Method for producing very-high or ultra-high molecular weight polyethylene

ABSTRACT

The field of the invention relates generally to a method for preparing very-high or ultra-high molecular weight polyethylene. More particularly, the present invention related to a method of preparing very-high or ultra-high molecular weight polyethylene using a supported catalyst comprising a support, an activator and a metal-ligand complex, as well as the catalyst itself. The present invention additionally relates to a method of using a supported catalyst comprising a support, an activator and co-supported metal-ligand complexes to obtain a bi-modal molecular weight distribution of polyethylene.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/645,030, filed Dec. 22, 2009 and now issued as U.S. Pat. No.8,637,618, which claims the benefit of priority from U.S. ProvisionalPatent Application Ser. No. 61/141,963, filed Dec. 31, 2008, the entirecontents of each of which are incorporated herein by reference.

BACKGROUND

The field of the invention relates generally to a method for preparingvery-high or ultra-high molecular weight polyethylene. Moreparticularly, the present invention relates to a method of preparingvery-high or ultra-high molecular weight polyethylene using a supportedcatalyst comprising a support, an activator and a metal-ligand complex,as well as the catalyst itself. The present invention additionallyrelates to a method of using a supported catalyst comprising a support,an activator and co-supported metal-ligand complexes to obtain very-highor ultra-high molecular weight polyethylene with a bi-modal molecularweight distribution.

Ancillary (or spectator) ligand-metal coordination complexes (e.g.,organometallic complexes) and compositions are useful as catalysts,additives, stoichiometric reagents, solid-state precursors, therapeuticreagents and drugs. Ancillary ligand-metal coordination complexes ofthis type can be prepared by combining an ancillary ligand with asuitable metal compound or metal precursor in a suitable solvent at asuitable temperature. The ancillary ligand contains functional groupsthat bind to the metal center(s), remain associated with the metalcenter(s), and therefore provide an opportunity to modify the steric,electronic and chemical properties of the active metal center(s) of thecomplex.

Certain known ancillary ligand-metal complexes and compositions arecatalysts for reactions such as oxidation, reduction, hydrogenation,hydrosilylation, hydrocyanation, hydroformylation, polymerization,carbonylation, isomerization, metathesis, carbon-hydrogen activation,carbon-halogen activation, cross-coupling, Friedel-Crafts acylation andalkylation, hydration, dimerization, trimerization, oligomerization,Diels-Alder reactions and other transformations.

One example of the use of these types of ancillary ligand-metalcomplexes and compositions is in the field of polymerization catalysis.In connection with single site catalysis, the ancillary ligand typicallyoffers opportunities to modify the electronic and/or steric environmentsurrounding an active metal center. This allows the ancillary ligand toassist in the creation of possibly different polymers. Group 4metallocene based single site catalysts are generally known forpolymerization reactions. See, generally, “Chemistry of CationicDicyclopentadienyl Group 4 Metal-Alkyl Complexes”, Jordan, Adv.Organometallic Chem., 1991, Vol. 32, pp. 325-153 and the referencestherein, all of which is incorporated herein by reference. Oneapplication for metallocene catalysts is in the production ofpolyolefins, such as in the production of polyethylene.

A type of polyethylene of particular value is ultra-high molecularweight polyethylene (“UHMWPE”). Ultra High Molecular Weight Polyethyleneis a valuable engineering plastic, with a unique combination of abrasionresistance, surface lubricity, chemical resistance, and impact strength,and very high tensile strength as a fiber. See, for example, Stein, H.L., Ultra High Molecular Weight Polyethylene (UHMWPE), pp. 167-171, inENGINEERED MATERIALS HANDBOOK, Volume 2: Engineering Plastics, ASMInternational, 1998. Industrial uses include, for example, liners forbulk material handling, nautical rope, truck bed linings and metal shaftbushings. UHMWPE is the product of a cheap monomer (ethylene) and arelatively simple process (typical slurry HDPE processes), using fairlyconventional Ziegler catalysts. See, for example, U.S. Pat. No.5,587,440 and EP 0575840 B1.

Ultra-high molecular weight polyethylene may typically be characterizedby a molecular weight of at least about 3×10⁶ g/mol, with molecularweights from about 3×10⁶ g/mol to about 10×10⁶ g/mol being typical. Incontrast, very-high molecular weight polyethylene may typically becharacterized by a molecular weight from about 1×10⁶ g/mol to less thanabout 3×10⁶ g/mol and high molecular weight polyethylene may typicallybe characterized by a molecular weight of greater than about 3×10⁵ g/molto less than about 1×10⁶ g/mol. Conventional UHMWPE resin does notexhibit a measurable melt index and cannot be processed usingconventional polyolefin melt processing techniques such as, for example,injection molding, blow molding, rotomolding or film blowing or casting.Rather, UHMWPE is conventionally processed by compression molding or ramextrusion. Compression molding and ram extrusion are relatively slowprocessing techniques and require products to be machined from theresulting sheets or rods. The main limitation to wider use of UHMWPE isthe difficulty of processability.

Broad or bimodal molecular weight distribution polymer compositions arecompositions that typically include one or more high molecular weightpolymers and one or more low molecular weight polymers. In bimodalmolecular weight distribution polymer compositions, the weight fractionof the high molecular weight polymer may range from, for example, 0.10to 0.90. The relative amount of high molecular weight polymer in thepolymer composition can influence the rheological properties of thecomposition. One such measurable rheological property of bimodal polymercompositions is its melt flow rate (e.g. I₂₁, measured at 190° C., witha 21.6 kg load according to ASTM D-1238). By increasing the weightfraction of low molecular weight polymers in the polymer composition,the polymer composition may generally exhibit improved flowcharacteristics.

Conventional techniques to improve the processability of UHMWPE involvethe melt blending of a lower molecular weight polymer with UHMWPEcompositions, or involve use of two reactors in series. Such techniqueshave generally proven to be insufficient due to difficulty in uniformlydispersing the lower molecular weight polymer into the composition. Suchpoorly blended compositions are characterized by a decrease in impactstrength and wear resistance compared to unblended UHMWPE.

While the melt processability to the UHMWPE can be greatly improved byblending with lower molecular weight polymers, this comes at the priceof reduction in the key desirable properties of UHMWPE. One problem isthe difficulty of achieving a homogeneous blended product. The extremelylow melt viscosity of the UHMWPE makes it very difficult to fullydissolve & disperse the UHMWPE particles, resulting in a “pumpableslurry” in the worst cases. This results in a marked decrease in impactstrength and wear resistance compared to unblended UHMWPE. See, forexample, U.S. Pat. No. 4,110,391, U.S. Pat. No. 4,281,070, U.S. Pat. No.4,786,687, U.S. Pat. No. 4,923,935, U.S. Pat. No. 5,079,287, U.S. Pat.No. 5,393,473, U.S. Pat. No. 5,422,061, U.S. Pat. No. 5,422,061, U.S.Pat. No. 5,658,992, U.S. Pat. No. 6,521,709, U.S. Pat. No. 6,790,923,and WO 02/046297.

Melt-processable blends of UHMWPE and HDPE (high density polyethylene)have also been prepared using 2-stage reactor technology. Typically,ethylene is polymerized in the absence of hydrogen to produce UHMWPE inthe first stage, then in the presence of hydrogen to produce lowermolecular weight HDPE in the second stage. Resulting granular productsare intra-granular blends. See for example U.S. Pat. No. 4,786,687, EP0274536 B2, both employing conventional Ziegler catalysts.

It has been demonstrated that bimodal polyethylenes may be prepared bysimultaneous polymerization of ethylene (and optionally α-olefincomonomer(s)) to produce a lower molecular weight polyethylene componentand a high molecular weight polyethylene component by use ofco-supported “bimetallic” catalysts in a single reactor (see, forexample, U.S. Pat. No. 5,032,562, U.S. Pat. No. 5,539,076, U.S. Pat. No.5,614,456, U.S. Pat. No. 6,051,525, WO 02/090393, WO 02/44222, and WO03/048213, the entire contents of which are incorporated herein byreference for all relevant and consistent purposes). The resultingcompositions possess a high degree of dispersion due to theintra-granular blending that occurs during the simultaneouspolymerization. Compared to series-reactor products, improvedintra-granular blending is possible by growing both componentssimultaneously. While these in-reactor blends produced by use ofco-supported catalysts in a single reactor have been demonstrated forpolyethylenes with regular and high molecular weights, catalyst systemscapable of producing bimodal ultra-high molecular weight polyethylenehave not been effectively demonstrated.

UHMWPE fibers are typically produced using a gel spinning process,typically using a 2-step process that produces fibers with highlyoriented UHMWPE chains, resulting in superb tensile strength. See, forexample, U.S. Pat. No. 4,137,394, U.S. Pat. No. 4,356,138, U.S. Pat. No.4,413,110, and U.S. Pat. No. 7,147,807. UHMWPE compositions with narrowmolecular weight distributions may offer improved properties for fiberapplications.

In view of the foregoing, a need continues to exist for catalystcompositions that may be used to prepare ultra-high molecular weightpolyolefins, and in particular UHMWPE compositions, with desirablemolecular weight distribution (MWD), either narrow MWD (e.g. for fiberapplications), or bimodal MWD (e.g. for improved melt flow properties).Additionally, a need exists for catalyst compositions that may be usedto produce UHMWPE compositions with a bimodal molecular weightdistribution, thus avoiding the need for blending and problemsassociated therewith. A further need exists for methods of producingUHMWPE that provide for the production of such polymers that have aspecific target molecular weight and molecular weight distribution.

BRIEF SUMMARY

Briefly, therefore, the present invention is directed to a slurrypolymerization method for producing a very-high ultra-high molecularweight polyethylene composition. The method comprises contacting one ormore monomers with a supported catalyst, the supported catalystcomprising: (i) a support; (ii) a metal-ligand complex deposited on thesupport at a loading of from about 1 μmol/gram of supported catalyst toabout 100 μmol/gram of supported catalyst, the metal-ligand complexcharacterized by the general formula:

wherein at least two of the bonds from the oxygens (O) to M arecovalent, with the other bonds being dative; AR is an aromatic groupthat can be the same or different from the other AR groups with each ARbeing independently selected from the group consisting of optionallysubstituted aryl and optionally substituted heteroaryl; B is a bridginggroup having from 3 to 50 atoms not counting hydrogen atoms and isselected from the group consisting of optionally substituted divalenthydrocarbyl and optionally substituted divalent heteroatom-containinghydrocarbyl; M is a metal selected from the group consisting of Hf andZr; each L is independently a moiety that forms a covalent dative orionic bond with M; and n′ is 1, 2, 3 or 4; and, (iii) an activator.

The present invention is further directed to a slurry polymerizationmethod for producing a very-high or ultra-high molecular weightpolyethylene composition. The method comprises contacting one or moremonomers with a two component co-supported catalyst, the co-supportedcatalyst comprising: (i) a support; (ii) two different metal-ligandcomplexes deposited on the support, wherein each metal-ligand complex isindependently characterized by the general formula:

wherein at least two of the bonds from the oxygens (O) to M arecovalent, with the other bonds being dative; AR is an aromatic groupthat can be the same or different from the other AR groups with each ARbeing independently selected from the group consisting of optionallysubstituted aryl and optionally substituted heteroaryl; B is a bridginggroup having from 3 to 50 atoms not counting hydrogen atoms and isselected from the group consisting of optionally substituted divalenthydrocarbyl and optionally substituted divalent heteroatom-containinghydrocarbyl; M is a metal selected from the group consisting of Hf andZr; each L is independently a moiety that forms a covalent dative orionic bond with M; and n′ is 1, 2, 3 or 4; and, (iii) an activator.

The present invention is still further directed to a slurrypolymerization method for producing a polyethylene composition having abroad or bimodal molecular weight distribution, the compositioncomprising a first polyethylene component that is a very-high orultra-high molecular weight polyethylene component and a secondpolyethylene component that is a very-high or high molecular weightpolyethylene component. The method comprises contacting one or moremonomers with a two component co-supported catalyst, the co-supportedcatalyst comprising: (i) a support; (ii) two different metal-ligandcomplexes deposited on the support, wherein each metal-ligand complex isindependently characterized by the general formula:

wherein at least two of the bonds from the oxygens (O) to M arecovalent, with the other bonds being dative; AR is an aromatic groupthat can be the same or different from the other AR groups with each ARbeing independently selected from the group consisting of optionallysubstituted aryl and heteroaryl; B is a bridging group having from 3 to50 atoms not counting hydrogen atoms and is selected from the groupconsisting of optionally substituted divalent hydrocarbyl and optionallysubstituted divalent heteroatom-containing hydrocarbyl; M is a metalselected from the group consisting of Hf and Zr; each L is independentlya moiety that forms a covalent dative or ionic bond with M; and n′ is 1,2, 3 or 4; and, (iii) an activator, wherein one of the metal-ligandcomplexes of the co-supported catalyst produces the first polyethylenecomponent and the other metal-ligand complex of the co-supportedcatalyst produces the second polyethylene component.

The present invention is still further directed to one or more of theabove-noted methods additionally comprising the step of isolating orobtaining an ultra-high molecular weight polymer after the supportedcatalyst (or co-supported catalyst) and the one or more monomers havebeen contacted.

The present invention is still further directed to one or more of thesupported catalysts (or co-supported catalysts) detailed in the methodsdescribed above or elsewhere herein.

Various refinements exist of the features noted in relation to theabove-mentioned aspects of the present invention. Further features mayalso be incorporated in the above-mentioned aspects of the presentinvention as well. These refinements and additional features may existindividually or in any combination. For instance, various featuresdiscussed below in relation to any of the illustrated embodiments of thepresent invention may be incorporated into any of the above-describedaspects of the present invention, alone or in any combination.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-8 illustrate Rapid GPC chromatograms of polymer productsprepared by use of four individual supported catalysts comprising ametal-ligand complex and four individual supported catalysts comprisingco-supported two component metal-ligand complexes as described inExamples 1-4 herein below.

DETAILED DESCRIPTION

Embodiments of the present invention include provisions for slurrypolymerization methods for producing very-high or ultra-high molecularweight polyethylene compositions using supported catalysts, thecatalysts comprising a support, an activator, and one or moremetal-ligand compositions or complexes, as well as the supportedcatalysts themselves. In some embodiments, the supported catalystsproduce highly advantaged UHMWPE resins, including bimodal MWD UHMWPEfrom co-supporting two (or more) catalysts, potentially suitable formelt processing techniques. In some embodiments, catalysts with a singlesupported complex may produce narrow MWD UHMWPE resins potentiallysuitable for fiber applications. These catalysts may offer control ofmolecular weight, molecular weight distribution (MWD), comonomerincorporation & comonomer distribution as a function of molecularweight, which is not achievable with conventional Ziegler catalysts.

Applicants have found that compared to conventional Ziegler catalysts,so called “single-site” catalysts based on metallocene or“post-metallocene” catalysts (including the biphenylphenol-basedcatalysts described in WO 2005/108406 and WO 2003/091262, the entirecontents of which are incorporated herein by reference for all relevantand consistent purposes), offer the advantages of narrow molecularweight distribution (MWD, a classic “single site” catalyst operatingwith statistical control of chain propagation & chain transfer isexpected to give a polymer product with a MWD of 2, compared to MWD ofaround 4 to 8 or more, typical of Ziegler catalysts). Also, compared toconventional Ziegler catalysts, so called “single-site” catalysts basedon metallocene or “post-metallocene” catalysts (including thebiphenylphenol-based catalysts described in WO 2005/108406 and WO2003/091262), offer the advantage of more uniform incorporation ofα-olefin comonomers into ethylene/α-olefin copolymers, including moreuniform incorporation of α-olefin comonomers as a function of molecularweight. Co-supported catalysts incorporating “single-site” catalystsbased on metallocene or “post-metallocene” catalysts offer control ofmolecular weight, molecular weight distribution (MWD), comonomerincorporation & comonomer distribution as a function of molecularweight, which is not achievable with conventional Ziegler catalysts(see, for example, WO 02/090393 and WO 03/048213).

As used herein, the phrase “characterized by the formula” is notintended to be limiting and is used in the same way that “comprising” iscommonly used. The term “independently selected” is used herein toindicate that the groups in question—e.g., R¹, R², R³, R⁴, and R⁵—can beidentical or different (e.g., R¹, R², R³, R⁴, and R⁵ may all besubstituted alkyls, or R¹ and R² may be a substituted alkyl and R³ maybe an aryl, etc.). Use of the singular includes use of the plural andvice versa (e.g., a hexane solvent, includes hexanes). A named R groupwill generally have the structure that is recognized in the art ascorresponding to R groups having that name. The terms “compound” and“complex” are generally used interchangeably in this specification, butthose of skill in the art may recognize certain compounds as complexesand vice versa. For the purposes of illustration, representative certaingroups are defined herein. These definitions are intended to supplementand illustrate, not preclude, the definitions known to those of skill inthe art.

“Optional” or “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where said event or circumstance occurs and instances where itdoes not. For example, the phrase “optionally substituted hydrocarbyl”means that a hydrocarbyl moiety may or may not be substituted and thatthe description includes both unsubstituted hydrocarbyl and hydrocarbylwhere there is substitution.

The term “alkyl” as used herein refers to a branched or unbranchedsaturated hydrocarbon group typically although not necessarilycontaining 1 to about 50 carbon atoms, such as methyl, ethyl, n-propyl,isopropyl, n-butyl, isobutyl, sec-butyl, t-butyl, octyl, decyl, and thelike, as well as cycloalkyl groups such as cyclopentyl, cyclohexyl andthe like. Generally, although again not necessarily, alkyl groups hereinmay contain 1 to about 20 carbon atoms. “Substituted alkyl” refers toalkyl substituted with one or more substituent groups (e.g., benzyl orchloromethyl), and the terms “heteroatom-containing alkyl” and“heteroalkyl” refer to alkyl in which at least one carbon atom isreplaced with a heteroatom (e.g., —CH₂OCH₃ is an example of aheteroalkyl).

The term “alkenyl” as used herein refers to a branched or unbranchedhydrocarbon group typically although not necessarily containing 2 toabout 50 carbon atoms and at least one double bond, such as ethenyl,n-propenyl, isopropenyl, n-butenyl, isobutenyl, octenyl, decenyl, andthe like. Generally, although again not necessarily, alkenyl groupsherein contain 2 to about 20 carbon atoms. “Substituted alkenyl” refersto alkenyl substituted with one or more substituent groups, and theterms “heteroatom-containing alkenyl” and “heteroalkenyl” refer toalkenyl in which at least one carbon atom is replaced with a heteroatom.

The term “alkynyl” as used herein refers to a branched or unbranchedhydrocarbon group typically although not necessarily containing 2 toabout 50 carbon atoms and at least one triple bond, such as ethynyl,n-propynyl, isopropynyl, n-butynyl, isobutynyl, octynyl, decynyl, andthe like. Generally, although again not necessarily, alkynyl groupsherein may have 2 to about 20 carbon atoms. “Substituted alkynyl” refersto alkynyl substituted with one or more substituent groups, and theterms “heteroatom-containing alkynyl” and “heteroalkynyl” refer toalkynyl in which at least one carbon atom is replaced with a heteroatom.

The term “aromatic” is used in its usual sense, including unsaturationthat is essentially delocalized across several bonds around a ring. Theterm “aryl” as used herein refers to a group containing an aromaticring. Aryl groups herein include groups containing a single aromaticring or multiple aromatic rings that are fused together, linkedcovalently, or linked to a common group such as a methylene or ethylenemoiety. More specific aryl groups contain one aromatic ring or two orthree fused or linked aromatic rings, e.g., phenyl, naphthyl, biphenyl,anthracenyl, or phenanthrenyl. In particular embodiments, arylsubstituents include 1 to about 200 atoms other than hydrogen, typically1 to about 50 atoms other than hydrogen, and specifically 1 to about 20atoms other than hydrogen. In some embodiments herein, multi-ringmoieties are substituents and in such embodiments the multi-ring moietycan be attached at an appropriate atom. For example, “naphthyl” can be1-naphthyl or 2-naphthyl; “anthracenyl” can be 1-anthracenyl,2-anthracenyl or 9-anthracenyl; and “phenanthrenyl” can be1-phenanthrenyl, 2-phenanthrenyl, 3-phenanthrenyl, 4-phenanthrenyl or9-phenanthrenyl.

The term “alkoxy” as used herein intends an alkyl group bound through asingle, terminal ether linkage; that is, an “alkoxy” group may berepresented as —O-alkyl where alkyl is as defined above. The term“aryloxy” is used in a similar fashion, and may be represented as—O-aryl, with aryl as defined below. The term “hydroxy” refers to —OH.

Similarly, the term “alkylthio” as used herein intends an alkyl groupbound through a single, terminal thioether linkage; that is, an“alkylthio” group may be represented as —S-alkyl where alkyl is asdefined above. The term “arylthio” is used similarly, and may berepresented as —S-aryl, with aryl as defined below. The term “mercapto”refers to —SH.

The term “allenyl” is used herein in the conventional sense to refer toa molecular segment having the structure —CH═C═CH₂. An “allenyl” groupmay be unsubstituted or substituted with one or more non-hydrogensubstituents.

The term “aryl” as used herein, and unless otherwise specified, refersto an aromatic substituent containing a single aromatic ring or multiplearomatic rings that are fused together, linked covalently, or linked toa common group such as a methylene or ethylene moiety. More specificaryl groups contain one aromatic ring or two or three fused or linkedaromatic rings, e.g., phenyl, naphthyl, biphenyl, anthracenyl,phenanthrenyl, and the like. In particular embodiments, arylsubstituents have 1 to about 200 carbon atoms, typically 1 to about 50carbon atoms, and specifically 1 to about 20 carbon atoms. “Substitutedaryl” refers to an aryl moiety substituted with one or more substituentgroups, (e.g., tolyl, mesityl and perfluorophenyl) and the terms“heteroatom-containing aryl” and “heteroaryl” refer to aryl in which atleast one carbon atom is replaced with a heteroatom (e.g., rings such asthiophene, pyridine, pyrazine, isoxazole, pyrazole, pyrrole, furan,thiazole, oxazole, imidazole, isothiazole, oxadiazole, triazole, etc. orbenzo-fused analogues of these rings, such as indole, carbazole,benzofuran, benzothiophene, etc., are included in the term“heteroaryl”). In some embodiments herein, multi-ring moieties aresubstituents and in such an embodiment the multi-ring moiety can beattached at an appropriate atom. For example, “naphthyl” can be1-naphthyl or 2-naphthyl; “anthracenyl” can be 1-anthracenyl,2-anthracenyl or 9-anthracenyl; and “phenanthrenyl” can be1-phenanthrenyl, 2-phenanthrenyl, 3-phenanthrenyl, 4-phenanthrenyl or9-phenanthrenyl.

The terms “halo” and “halogen” are used in the conventional sense torefer to a chloro, bromo, fluoro or iodo substituent.

The terms “heterocycle” and “heterocyclic” refer to a cyclic radical,including ring-fused systems, including heteroaryl groups as definedbelow, in which one or more carbon atoms in a ring is replaced with aheteroatom—that is, an atom other than carbon, such as nitrogen, oxygen,sulfur, phosphorus, boron or silicon. Heterocycles and heterocyclicgroups include saturated and unsaturated moieties, including heteroarylgroups as defined below. Specific examples of heterocycles includepyrrolidine, pyrroline, furan, tetrahydrofuran, thiophene, imidazole,oxazole, thiazole, indole, and the like, including any isomers of these.Additional heterocycles are described, for example, in Alan R.Katritzky, Handbook of Heterocyclic Chemistry, Pergammon Press, 1985,and in Comprehensive Heterocyclic Chemistry, A. R. Katritzky et al.,eds, Elsevier, 2d. ed., 1996. The term “metallocycle” refers to aheterocycle in which one or more of the heteroatoms in the ring or ringsis a metal.

The term “heteroaryl” refers to an aryl radical that includes one ormore heteroatoms in the aromatic ring. Specific heteroaryl groupsinclude groups containing heteroaromatic rings such as thiophene,pyridine, pyrazine, isoxazole, pyrazole, pyrrole, furan, thiazole,oxazole, imidazole, isothiazole, oxadiazole, triazole, and benzo-fusedanalogues of these rings, such as indole, carbazole, benzofuran,benzothiophene and the like.

More generally, the modifiers “hetero” and “heteroatom-containing”, asin “heteroalkyl” or “heteroatom-containing hydrocarbyl group” refer to amolecule or molecular fragment in which one or more carbon atoms isreplaced with a heteroatom. Thus, for example, the term “heteroalkyl”refers to an alkyl substituent that is heteroatom-containing. When theterm “heteroatom-containing” introduces a list of possibleheteroatom-containing groups, it is intended that the term apply toevery member of that group. That is, the phrase “heteroatom-containingalkyl, alkenyl and alkynyl” is to be interpreted as“heteroatom-containing alkyl, heteroatom-containing alkenyl andheteroatom-containing alkynyl.”

“Hydrocarbyl” refers to hydrocarbyl radicals containing 1 to about 50carbon atoms, specifically 1 to about 24 carbon atoms, most specifically1 to about 16 carbon atoms, including branched or unbranched, saturatedor unsaturated species, such as alkyl groups, alkenyl groups, arylgroups, and the like. The term “lower hydrocarbyl” intends a hydrocarbylgroup of one to six carbon atoms, specifically one to four carbon atoms.

By “substituted” as in “substituted hydrocarbyl,” “substituted aryl,”“substituted alkyl,” and the like, as alluded to in some of theaforementioned definitions, is meant that in the hydrocarbyl, alkyl,aryl or other moiety, at least one hydrogen atom bound to a carbon atomis replaced with one or more substituent groups such as hydroxy, alkoxy,alkylthio, phosphino, amino, halo, silyl, and the like. When the term“substituted” appears prior to a list of possible substituted groups, itis intended that the term apply to every member of that group. That is,the phrase “substituted alkyl, alkenyl and alkynyl” is to be interpretedas “substituted alkyl, substituted alkenyl and substituted alkynyl.”Similarly, “optionally substituted alkyl, alkenyl and alkynyl” is to beinterpreted as “optionally substituted alkyl, optionally substitutedalkenyl and optionally substituted alkynyl.”

The term “saturated” refers to the lack of double and triple bondsbetween atoms of a radical group such as ethyl, cyclohexyl,pyrrolidinyl, and the like. The term “unsaturated” refers to thepresence of one or more double and triple bonds between atoms of aradical group such as vinyl, allyl, acetylide, oxazolinyl, cyclohexenyl,acetyl and the like, and specifically includes alkenyl and alkynylgroups, as well as groups in which double bonds are delocalized, as inaryl and heteroaryl groups as defined below.

By “divalent” as in “divalent hydrocarbyl”, “divalent alkyl”, “divalentaryl” and the like, is meant that the hydrocarbyl, alkyl, aryl or othermoiety is bonded at two points to atoms, molecules or moieties with thetwo bonding points being covalent bonds.

As used herein the term “silyl” refers to the —SiZ¹Z²Z³ radical, whereeach of Z¹, Z², and Z³ is independently selected from the groupconsisting of hydrogen and optionally substituted alkyl, alkenyl,alkynyl, heteroatom-containing alkyl, heteroatom-containing alkenyl,heteroatom-containing alkynyl, aryl, heteroaryl, alkoxy, aryloxy, amino,silyl and combinations thereof.

As used herein the term “boryl” refers to the —BZ¹Z² group, where eachof Z¹ and Z² is as defined above. As used herein, the term “phosphino”refers to the group —PZ¹Z², where each of Z¹ and Z² is as defined above.As used herein, the term “phosphine” refers to the group: PZ¹Z²Z³, whereeach of Z¹, Z³ and Z² is as defined above. The term “amino” is usedherein to refer to the group —NZ¹Z², where each of Z¹ and Z² is asdefined above. The term “amine” is used herein to refer to the group:NZ¹Z²Z³, where each of Z¹, Z² and Z³ is as defined above.

Other abbreviations used herein include: “Pr” to refer to isopropyl;“^(t)Bu” to refer to tert-butyl; “Me” to refer to methyl; “Et” to referto ethyl; “Ph” to refer to phenyl; “Mes” to refer to mesityl(2,4,6-trimethyl phenyl); “TFA” to refer to trifluoroacetate; “THF” torefer to tetrahydrofuran; “Np” refers to napthyl; “Cbz” refers tocarbazolyl; “Ant” refers to anthracenyl; and “H₈-Ant” refers to1,2,3,4,5,6,7,8-octahydroanthracenyl; “Bn” refers to benzyl; “Ac” refersto CH₃CO; “EA” refers to ethyl acetate; “Ts” refers to tosyl or,synonymously, para-toluenesulfonyl; “THP” refers to tetrahydropyran;“dppf” refers to 1,1′-bis(diphenylphosphino)ferrocenel; “MOM” refers tomethoxymethyl.

“Polyethylene” means a polymer made 90% ethylene-derived units, or 95%ethylene-derived units, or 100% ethylene-derived units. The polyethylenecan thus be a homopolymer or a copolymer, including a terpolymer, havingother monomeric units. A polyethylene described herein can, for example,include at least one or more other olefins) and/or comonomer(s). Theolefins, for example, can contain from 3 to 16 carbon atoms in oneembodiment; from 3 to 12 carbon atoms in another embodiment; from 4 to10 carbon atoms in another embodiment; and from 4 to 8 carbon atoms inyet another embodiment. Illustrative comonomers include, but are notlimited to, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene,1-octene, 4-methylpent-1-ene, 1-decene, 1-dodecene, 1-hexadecene and thelike. Also utilizable herein are polyene comonomers such as1,3-hexadiene, 1,4-hexadiene, cyclopentadiene, dicyclopentadiene,4-vinylcyclohex-1-ene, 1,5-cyclooctadiene, 5-vinylidene-2-norbornene and5-vinyl-2-norbornene. Other embodiments may include ethacrylate ormethacrylate.

“Ultra-high molecular weight polyethylene” refers to polyethylenecompositions with weight-average molecular weight of at least about3×10⁶ g/mol. In some embodiments, the molecular weight of the ultra-highmolecular weight polyethylene composition is between about 3×10⁶ g/moland about 20×10⁶ g/mol, or about 3×10⁶ g/mol and about 15×10⁶ g/mol, orabout 3×10⁶ g/mol and about 10×10⁶ g/mol, or about 3×10⁶ g/mol and about6×10⁶ g/mol. For purposes of the present specification, the molecularweights referenced herein are determined in accordance with theMargolies equation (“Margolies molecular weight”).

“Very-high molecular weight polyethylene” refers to polyethylenecompositions with a weight average molecular weight of less than about3×10⁶ g/mol and more than about 1×10⁶ g/mol. In some embodiments, themolecular weight of the very-high molecular weight polyethylenecomposition is between about 2×10⁶ g/mol and less than about 3×10⁶g/mol.

The term “bimodal” refers to a polymer or polymer composition, e.g.,polyethylene, having a “bimodal molecular weight distribution.” A“bimodal” composition can include a polyethylene component with at leastone identifiable higher molecular weight and a polyethylene componentwith at least one identifiable lower molecular weight, e.g., twodistinct peaks on an SEC curve (GPC chromatogram). A material with morethan two different molecular weight distribution peaks will beconsidered “bimodal” as that term is used although the material may alsobe referred to as a “multimodal” composition, e.g., a trimodal or eventetramodal, etc. composition.

The term “broad” as in “broad molecular weight distribution” includesthe case where a polyethylene composition is comprised of a blend ofhigher and lower molecular weight components but where there are not twodistinct peaks on an SEC curve (GPC chromatogram), but rather a singlepeak which is broader than the individual component peaks.

So called “single-site” catalysts based on metallocene or“post-metallocene” catalysts (including the biphenylphenol-basedcatalysts described in WO 2005/108406 and WO 2003/091262) are capable ofproducing narrow molecular weight distribution (MWD) polymer products. Aclassic “single site” catalyst operating with statistical control ofchain propagation & chain transfer is expected to give a polymer productwith a MWD of 2, compared to a “broad” MWD of around 4 to 8 or moretypical of Ziegler catalysts, which are considered to be multi-sitecatalysts.

“Ultra-high molecular weight polyethylene component” refers to apolyethylene component in the bimodal composition with a weight averagemolecular weight of at least about 3×10⁶ g/mol. In some embodiments, theultra-high molecular weight polyethylene component has a weight averagemolecular weight between about 3×10⁶ g/mol and about 20×10⁶ g/mol, orbetween about 3×10⁶ g/mol and about 15×10⁶ g/mol, or between about 3×10⁶g/mol and about 10×10⁶ g/mol, or between about 3×10⁶ g/mol and about6×10⁶ g/mol. When the composition includes more than two components,e.g., a trimodal composition, the multimodal composition may have morethan one ultra-high molecular weight component.

“Very-high molecular weight polyethylene component” refers to apolyethylene component in the bimodal (or multimodal) composition with aweight average molecular weight of less than about 3×10⁶ g/mol (e.g.,less than about 2.75×10⁶ g/mol, about 2.5×10⁶ g/mol, about 2.25×10⁶g/mol, or even about 2×10⁶ g/mol) and more than about 1×10⁶ g/mol (e.g.,more than about 1.5×10⁶ g/mol, or about 2×10⁶ g/mol). “High-molecularweight polyethylene component” refers to a polyethylene component in thebimodal (or multimodal) composition with a weight average molecularweight of less than about 1×10⁶ g/mol (e.g., less than about 7.5×10⁵g/mol, or even less than about 5×10⁵ g/mol) and more than about 3×10⁵g/mol (e.g., more than 3.5×10⁵ g/mol, or even more than 4×10⁵ g/mol).When the composition includes more than two components, e.g., a trimodalcomposition, the multimodal composition may have more than one highmolecular weight components, more than one very-high molecular weightcomponents or at least one high molecular weight component and at leastone very-high molecular weight component.

Ligands

The ligands disclosed herein, which may be suitable for use in asupported (or co-supported) catalyst of the present invention, can bedescribed in a number of different ways. Thus, the ligands can bedescribed as dianionic, chelating ligands that may occupy up to fourcoordination sites of a single metal atom. The ligands can also bedescribed as diaionic ligands that, when chelated to a metal atom, format least one or two seven member metalocycles (counting the metal atomas one member of the seven member ring). Alternatively, the ligands canbe described as dianionic, chelating ligands that use either oxygen orsulfur as binding atoms to the metal atom. In still other alternatives,the ligands can be described as non-metallocene ligands that cancoordinate in an approximate C₂-symmetrical complex with a metal atom.These descriptions are not mutually exclusive, and can be used togetheror separately.

For example, ligands suitable for use in the method of the invention maybe characterized by the following general formula:

wherein each ligand has at least two hydrogen atoms capable of removalin a binding reaction with a metal atom or metal precursor or base; ARis an aromatic group that can be the same as or different from the otherAR groups with, generally, each AR being independently selected from thegroup consisting of optionally substituted aryl or optionallysubstituted heteroaryl; and B is a bridging group having from 3 to 50atoms (not counting hydrogen atoms). In one preferred embodiment, B is abridge of between about 3 and about 20 carbon atoms (not includinghydrogen atoms).

Generally, the “upper aromatic ring” is the ring to which the hydroxylsare bonded or part of. Similarly, the “lower aromatic ring” is the ringto which the oxygens are bonded or part of. In some embodiments, AR-AR(that is, the structure formed from one upper aromatic ring and itscorresponding lower aromatic ring) is a biaryl species, morespecifically a biphenyl.

In some embodiments, the bridging group B is selected from the groupconsisting of divalent hydrocarbyl and divalent heteroatom containinghydrocarbyl (including, for example, between about 3 and about 20 carbonatoms), which may be optionally substituted. In more particularembodiments, B is selected from the group consisting of optionallysubstituted divalent alkyl, alkenyl, alkynyl, heteroalkyl,heteroalkenyl, heteroalkynyl, aryl, heteroaryl and silyl. In any ofthese embodiments, the bridging group can be substituted with one ormore optionally substituted hydrocarbyl or optionally substitutedheteroatom-containing hydrocarbyl groups, such as optionally substitutedalkyl, alkenyl, alkynyl, heteroalkyl, heteroalkenyl, heteroalkynyl,aryl, or heteroaryl. It should be noted that these substitutions are inaddition to the bonds between the bridging group B and the oxygen atomsin formula I. Two or more of the hydrocarbyl or heteroatom-containinghydrocarbyl groups can be joined into a ring structure having from 3 to50 atoms in the ring structure (not counting hydrogen atoms). In someembodiments in which the bridging group includes one or more ringstructures, it may be possible to identify more than one chain of bridgeatoms extending from the oxygen atoms, and in such cases it can beconvenient to define the “bridge” as the shortest path of connectivitybetween the oxygen atoms, and the “substituents” as the groups bonded toatoms in the bridge. Where there are two alternative, equally shortpaths of connectivity, the bridge can be defined along either path.

In still other embodiments, B can be represented by the general formula-(Q″R⁴⁰ _(2-z″))_(z′)— wherein each Q″ is independently either carbon orsilicon and where each R⁴⁰ is independently selected from the groupconsisting of hydrogen and optionally substituted hydrocarbyl oroptionally substituted heteroatom-containing hydrocarbyl. Two or moreR⁴⁰ groups may be joined into a ring structure having from 3 to 50 atomsin the ring structure (not counting hydrogen atoms). In theseembodiments, z′ is an integer from 1 to 10, more specifically from 1 to5 and even more specifically from 2-5, and z″ is 0, 1 or 2. For example,when z″ is 2, there is no R⁴⁰ group associated with Q″, which allows forthose cases where one Q″ is multiply bonded to a second Q″. In morespecific embodiments, R⁴⁰ is selected from the group consisting ofhydrogen, halogen, and optionally substituted alkyl, alkenyl, alkynyl,heteroalkyl, heteroalkenyl, heteroalkynyl, aryl, heteroaryl, alkoxyl,aryloxyl, silyl, boryl, phosphino, amino, alkylthio, arylthio, andcombinations thereof, where at least one R⁴⁰ group in B is not hydrogen.In any of the embodiments mentioned above, the B group can include oneor more chiral centers. Thus, for example, B can be represented by theformula —CHR⁵⁰—(CH₂)_(m)—CHR⁵¹—, where R⁵⁰ and R⁵¹ are independentlyselected from the group consisting of optionally substituted alkyl,heteroalkyl, aryl or heteroaryl, R⁵⁰ and R⁵¹ can be arranged in anyrelative configuration (e.g., syn/anti, threo/erythro, or the like), andwhere the ligand can be generated as a racemic mixture or in anenantiomerically pure form.

In particular embodiments, the bridging group B includes a chain of oneor more bridge atoms extending from the oxygen atoms and one or more ofthe bridge atoms situated adjacent to one or both of the oxygen atoms isbonded to one or more substituents (not counting bonds to one or both ofthe oxygen atoms or neighboring bridge atoms along the chain, as notedabove), where the substituents are independently selected from the groupconsisting of optionally substituted alkyl, heteroalkyl, aryl andheteroaryl. In more particular embodiments, the bridging group B issubstituted with a plurality of substituents that are independentlyselected from the group consisting of optionally substituted alkyl,heteroalkyl, aryl and heteroaryl, such that each of the bridge atomsthat is adjacent to one or both of the oxygen atoms is bonded to atleast one substituent, again not counting bonds to the oxygen atoms orneighboring bridge atoms. In such embodiments, two or more of thesubstituents can be joined into a ring structure having from 3 to 50atoms in the ring structure (not counting hydrogen atoms).

Thus, in some embodiments, the O—B—O fragment can be characterized byone of the following formulae:

where each Q is independently selected from the group consisting ofcarbon and silicon, each R⁶⁰ is independently selected from the groupconsisting of hydrogen and optionally substituted hydrocarbyl andheteroatom containing hydrocarbyl, provided that at least one R⁶⁰substituent is not hydrogen, wherein the R⁶⁰ substituents are optionallyjoined into a ring structure having from 3 to 50 atoms in the ringstructure not counting hydrogen atoms, and m′ is 0, 1, 2 or 3. SpecificO—B—O fragments within these embodiments include, for example,O—(CH₂)₃—O, O—(CH₂)₄—O, O—CH(CH₃)—CH(CH₃)—O, O—CH₂—CH(CH₃)—CH₂—O,O—CH₂—C(CH₃)₂—CH₂—O, O—CH₂—CH(CHMe₂)—CH₂—O′, O—CH₂—CH(C₆H₅)—CH₂—O,O—CH(CH₃)—CH₂—CH(CH₃)—O, O—CH(C₂H₅)—CH₂—CH(C₂H₅)—O,O—CH(CH₃)CH₂CH₂CH(CH₃)—O, O—CH(C₆H₅)CH₂CH(C₆H₅)—O,

Other specific bridging moieties are set forth in the example ligandsand complexes herein.

In particular embodiments, the ligands can be characterized by thegeneral formula:

wherein each of R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹², R¹³, R¹⁴, R¹⁵, R¹⁶,R¹⁷, R¹⁸, and R¹⁹ is independently selected from the group consisting ofhydrogen, halogen, and optionally substituted hydrocarbyl,heteroatom-containing hydrocarbyl, alkoxy, aryloxy, silyl, boryl,phosphino, amino, alkylthio, arylthio, nitro, and combinations thereof;optionally two or more R groups can combine together into ringstructures (for example, single ring or multiple ring structures), withsuch ring structures having from 3 to 12 atoms in the ring (not countinghydrogen atoms); and B is a bridging group as defined above.

In more specific embodiments, each of R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹,R¹², R¹³, R¹⁴, R¹⁵, R¹⁶, R¹⁷, R¹⁸, and R¹⁹ is independently selectedfrom the group consisting of hydrogen, halogen, and optionallysubstituted alkyl, heteroalkyl, aryl, heteroaryl, alkoxyl, aryloxyl,silyl, amino, alkylthio and arylthio. In some embodiments, at least oneof R² and R¹² is not hydrogen and in still other embodiments both R² andR¹² are not hydrogen.

In more specific embodiments, R² and R¹² are selected from the groupconsisting of an aryl and a heteroaryl (e.g., phenyl, substitutedphenyl, antrazenyl carbozyl, mesityl, 3,5-(t-Bu)₂-phenyl and the like);R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹³, R¹⁴, R¹⁵, R¹⁶, R¹⁷, R¹⁸, and R¹⁹ aredefined as above; and B is:

wherein Q, R⁶⁰ and m′ are as defined above.

In another specific embodiment, R² and R¹² are independently selectedfrom the group consisting of substituted or unsubstituted moieties ofthe general formulae:

wherein the denoted broken bonds are points of attachment to theremaining portion of the molecule; R⁴ and R¹⁴ are each an alkyl; R³, R⁵,R⁶, R⁷, R⁸, R⁹, R¹³, R¹⁵, R¹⁶, R¹⁷, R¹⁸, and R¹⁹ are hydrogen, and B isselected from the group consisting of:

The illustrated structures are provided for purposes of illustration andshould not be viewed in a limiting sense. For example, one or more ofthe rings may be substituted with one of more substituents selectedfrom, for example, Me, iPr, Ph, Bn, tBu, and the like.

While the moiety of the following formula includes three methylsubstituents,

it should be known that one or more of the methyl groups may be replacedby a hydrogen or some other suitable substituent (e.g., lower alkyl,such as methyl, ethyl, etc.), and/or may be positioned elsewhere on thering without departing from the intended scope of the present invention.

In more specific embodiments, the ligands can be characterized by theformula:

In formula III, each of R², R³, R⁴, R⁵, R⁶, R⁷, R⁸ and R⁹ independentlyselected from the group consisting of hydrogen, halogen, and optionallysubstituted alkyl, alkenyl, alkynyl, heteroalkyl, heteroalkenyl,heteroalkynyl, aryl, heteroaryl, alkoxyl, aryloxyl, silyl, boryl,phosphino, amino, mercapto, alkylthio and arylthio, nitro, andcombinations thereof. The remaining substituent B is defined as above.

In more specific embodiments, R² is selected from the group consistingof an aryl and a heteroaryl; R⁴ is alkyl; R³, R⁵, R⁶, R⁷, R⁸ and R⁹ arehydrogen; and B is:

wherein Q, R⁶⁰, and m′ are as defined above.

In another particular embodiment, R² is selected from the groupconsisting of substituted or unsubstituted moieties of the generalformulae:

R⁴ is an alkyl; R³, R⁵, R⁶, R⁷, R⁸ and R⁹ are defined as above; and B isselected from the group consisting of:

In one embodiment, ligands are selected from the group consisting of thestructures illustrated in Table 1, below:

TABLE 1

and

The choice of particular R and B groups can have a strong influence onthe polymerization of olefins. Thus, the choice of substituent canaffect catalyst activity, thermal stability, the molecular weight of theproduct polymer, the degree and/or kind of stereo- or regioerrors, aswell as other factors known to be significant in the production ofvarious polymers.

In some embodiments, substituents can be selected to affect solubilityof the resulting ligand, complex or catalyst. For example, in some suchembodiments R⁴ and/or R¹⁴ can be selected from alkyl groups having 4 ormore carbons, 6 or more carbons, or 10 or more carbons.

Certain of these ligands are preferred for the polymerization of certainmonomers in a catalytic composition and/or in a metal complex. Thesecertain embodiments are discussed further below.

Ligand Preparation

Generally speaking, in one or more embodiments, the ligands disclosedherein, which may be suitable for use in a supported (or co-supported)catalyst of the invention, can be prepared using known procedures, suchas those described, for example, in March, Advanced Organic Chemistry,Wiley, New York 1992 (4^(th) Ed.). More specifically, the ligands of theinvention can be prepared using a variety of synthetic routes, dependingon the variation desired in the ligand. In general, the ligands areprepared in a convergent approach by preparing building blocks that arethen linked together either directly or with a bridging group.Variations in the R group substituents can be introduced in thesynthesis of the building blocks. Variations in the bridge can beintroduced with the synthesis of the bridging group. The preparation ofsuitable ligands has also been described in detail in, for example, WO03/091262, WO 2005/0084106, U.S. Pat. No. 7,060,848, U.S. Pat. No.7,091,292, U.S. Pat. No. 7,126,031, U.S. Pat. No. 7,241,714, U.S. Pat.No. 7,241,715, and U.S. Patent Publication No. 2008/0269470; the entirecontents of which are incorporated herein by reference for all relevantand consistent purposes.

Metal Precursor Compounds

Once the desired ligand is formed, it may be combined with a metal atom,ion, compound or other metal precursor compound. For example, in someembodiments, the metal precursors are activated metal precursors, whichrefers to a metal precursor (described below) that has been combined orreacted with an activator (described below) prior to combination orreaction with the ancillary ligand. As noted above, in one aspect theinvention relates to compositions that include such combinations ofligand and metal atom, ion, compound or precursor. In some applications,the ligands are combined with a metal compound or precursor and theproduct of such combination is not determined, if a product forms. Forexample, the ligand may be added to a reaction vessel at the same timeas the metal or metal precursor compound along with the reactants,activators, scavengers, etc. Additionally, the ligand can be modifiedprior to addition to or after the addition of the metal precursor, e.g.through a deprotonation reaction or some other modification.

In general, the metal precursor compounds may be characterized by thegeneral formula M(L)_(n) where M is a metal selected from the groupconsisting of groups 3-6 and lanthanide elements of the periodic tableof elements, more specifically, from group 4, and even more specificallyis selected from Hf and Zr. Each L is a ligand independently selectedfrom the group consisting of hydrogen, halogen, optionally substitutedalkyl, heteroalkyl, allyl, diene, alkenyl, heteroalkenyl, alkynyl,heteroalkynyl, aryl, heteroaryl, alkoxy, aryloxy, boryl, silyl, amino,phosphino, ether, thioether, phosphine, amine, carboxylate, alkylthio,arylthio, 1,3-dionate, oxalate, carbonate, nitrate, sulfate, andcombinations thereof. Optionally, two or more L groups are joined into aring structure. One or more of the ligands L may also be ionicallybonded to the metal M and, for example, L may be a non-coordinated orloosely coordinated or weakly coordinated anion (e.g., L may be selectedfrom the group consisting of those anions described below in theconjunction with the activators); and optionally two or more L groupsmay be linked together in a ring structure. (See, e.g., Marks et al.,Chem. Rev. 2000, 100, 1391-1434 for a detailed discussion of these weakinteractions.) The subscript n is 1, 2, 3, 4, 5, or 6. The metalprecursors may be monomeric, dimeric or higher orders thereof.

Specific examples of suitable hafnium and zirconium precursors include,but are not limited: HfCl₄, Hf(CH₂Ph)₄, Hf(CH₂CMe₃)₄, Hf(CH₂SiMe₃)₄,Hf(CH₂Ph)₃Cl, Hf(CH₂CMe₃)₃Cl, Hf(CH₂SiMe₃)₃Cl, Hf(CH₂Ph)₂Cl₂,Hf(CH₂CMe₃)₂Cl₂, Hf(CH₂SiMe₃)₂Cl₂, Hf(NMe₂)₄, Hf(NEt₂)₄,Hf(N(SiMe₃)₂)₂Cl₂, Hf(N(SiMe₃)CH₂CH₂CH₂N(SiMe₃))Cl₂, and,Hf(N(Ph)CH₂CH₂CH₂N(Ph))Cl₂, as well as ZrCl₄, Zr(CH₂Ph)₄, Zr(CH₂CMe₃)₄,Zr(CH₂SiMe₃)₄, Zr(CH₂Ph)₃Cl, Zr(CH₂CMe₃)₃Cl, Zr(CH₂SiMe₃)₃Cl,Zr(CH₂Ph)₂Cl₂, Zr(CH₂CMe₃)₂Cl₂, Zr(CH₂SiMe₃)₂Cl₂, Zr(NMe₂)₄, Zr(NEt₂)₄,Zr(NMe₂)₂Cl₂, Zr(NEt₂)₂Cl₂, Zr(N(SiMe₃)₂)₂Cl₂,Zr(N(SiMe₃)CH₂ZrCH₂CH₂N(SiMe₃))Cl₂, and Zr(N(Ph)CH₂CH₂CH₂N(Ph))Cl₂.Lewis base adducts of these examples are also suitable as metalprecursors, for example, ethers, amines, thioethers, phosphines and thelike are suitable as Lewis bases. Specific examples include HfCl₄(THF)₂,HfCl₄(SMe₂)₂ and Hf(CH₂Ph)₂Cl₂(OEt₂). Activated metal precursors may beionic or zwitterionic compounds, such as [M(CH₂Ph)₃ ⁺][B(C₆F₅)₄ ⁻] or[M(CH₂Ph)₃ ⁺][PhCH₂B(C₆F₅)₃ ⁻] where M is Zr or HE Activated metalprecursors or such ionic compounds can be prepared in the manner shownin Pellecchia et al., Organometallics, 1994, 13, 298-302; Pellecchia etal., J. Am. Chem. Soc., 1993, 115, 1160-1162; Pellecchia et al.,Organometallics, 1993, 13, 3773-3775 and Bochmann et al.,Organometallics, 1993, 12, 633-640, each of which is incorporated hereinby reference.

The ligand to metal precursor compound ratio is typically in the rangeof about 0.1:1 to about 10:1, or about 0.5:1 to about 5:1, or about0.75:1 to about 2.5:1, and more specifically about 1:1.

As also noted above, in another aspect the invention relates tometal-ligand complexes. Generally, the ligand (or optionally a modifiedligand as discussed above) is mixed with a suitable metal precursor (andoptionally other components, such as activators) prior to orsimultaneously with allowing the mixture to be contacted with thereactants (e.g., monomers). When the ligand is mixed with the metalprecursor compound, a metal-ligand complex may be formed, which may besupported with an appropriate activator to form a supported catalyst (orco-supported catalyst) suitable for use in accordance with the presentinvention.

Metal-Ligand Complexes

The metal-ligand complexes according to the invention, which may besupported with an activator to form a catalyst of the present invention,can in general be described in a number of overlapping or alternativeways. Thus, the metal-ligand complexes can be described as complexeshaving dianionic, chelating ligands that may occupy up to fourcoordination sites of the metal atom. The metal-ligand complexes canalso be described as having dianionic ligands that form two seven-membermetallocycles with the metal atom (counting the metal atom as one memberof the seven member ring). Also, in some embodiments, the metal-ligandcomplexes can be described as having dianionic, chelating ligands thatuse oxygen as binding atoms to the metal atom.

Also, in some embodiments, the metal-ligand complexes can be describedas having ligands that can coordinate in at least two approximate C₂symmetric complex isomers. By approximate C₂ symmetry it is meant thatthe ligand coordinates with a metal such that the ligand parts occupyfour quadrants around the metal center extending towards the ligands Lin an approximate C₂ symmetric fashion, and approximate means that truesymmetry may not exist due to several factors that effect symmetry,including, for example, the effect of the bridge. In these embodiments,the conformation of the ligand around the metal can be described aslambda or delta. At least two isomeric complexes can be formed which maybe enantiomeric or diastereomeric to each other. For ligands containingone or more chiral centers (e.g., substituted bridges with chiralcenters), diastereomeric metal-ligand complexes can be formed. Thediastereomeric complexes formed by a particular ligand-metal precursorcombination can be used as mixtures of diastereomers, or can beseparated and used as diastereomerically-pure complexes.

These isomeric structures may be separately formed by employing suitablemetal precursors containing appropriately substituted ligands (such aschelating bis-amide, bis-phenol, or diene ligands, as described below),which may strongly influence the stereochemistry of complexationreactions. It is known that group 4 metal complexes containing chelatingligands can be used as metal precursors in complexation reactions withthe bridged bis-cyclopentadienyl ligands to control the stereochemistryof the resulting bridged metallocene complex, as is described in Zhanget al., J. Am. Chem. Soc., 2000; 122, 8093-8094, LoCoco et al.,Organometallics, 2003, 22, 5498-5503, and Chen et al., J. Am. Chem.Soc., 2004, 126, 42-43. The use of analogous Group 4 metal precursorscontaining appropriately substituted chelating ligands in complexationreactions with the bridged bis(biaryl) ligands described herein mayprovide a mechanism to influence the stereochemistry of the resultingchiral approximately C₂-symmetric metal-ligand complexes. The use ofanalogous chiral Group 4 metal precursors containing appropriatelysubstituted chelating ligands that possess one or more chiral centersmay provide a mechanism to influence the absolute stereochemistry of theresulting chiral approximately C₂-symmetric metal-ligand complexes. Theuse of substantially enantiomerically pure chiral Group 4 metalprecursors containing appropriately substituted chelating ligands thatpossess one or more chiral centers may provide a mechanism to preparesubstantially enantiomerically or diastereomerically pure approximatelyC₂-symmetric metal-ligand complexes of this invention.

In some cases, it may also be possible to separate mixtures ofenantiomers or diastereomers by means of diastereomeric/enantiomericresolution using a chiral reagent. See, for example, Ringwald et al., J.Am. Chem. Soc., 1999, 121, pp. 1524-1527.

The various diastereomeric complexes may have different polymerizationperformance when used as catalysts for polymerizations, resulting, forexample, in the formation of polymer products having bimodal molecularweight and/or composition distribution.

In some embodiments, metal-ligand complexes according to an aspect ofthe invention can be characterized by the general formula:(4,2,O,S)ML_(n′)  (IV)where (4,2,O,S) is a dianionic ligand having at least 4 atoms that areeach independently oxygen or sulfur and chelating to the metal M at 4coordination sites through oxygen and/or sulfur atoms with two of thebonds between the oxygen or sulfur atoms and the metal being covalent innature and two of the bonds being dative in nature (i.e., oxygen orsulfur atoms acting as Lewis bases and the metal center acting as aLewis acid); M is a metal selected from the group consisting of groups3-6 and lanthanide elements of the periodic table of elements, morespecifically, from group 4 (e.g., Hf or Zr); each L is independentlyselected from the group consisting of hydrogen, halogen, optionallysubstituted alkyl, heteroalkyl, allyl, diene, alkenyl, heteroalkenyl,alkynyl, heteroalkynyl, aryl, heteroaryl, alkoxy, aryloxy, boryl, silyl,amino, phosphino, ether, thioether, phosphine, amine, carboxylate,alkylthio, arylthio, 1,3-dionate, oxalate, carbonate, nitrate, sulfate,and combinations thereof; and optionally two or more L groups may belinked together in a ring structure; n′ is 1, 2, 3, or 4.

In other embodiments, metal-ligand complexes according to the inventioncomprise two seven-member metallocycles formed with bonds from the metalatom to at least 2 heteroatoms (e.g., O, S, N, P and the like). In morespecific forms, these metal-ligand complexes comprise two seven-membermetallocycles and even more specifically, there are at least twoseven-member metallocycles that are joined together by at least onebridging group. In still other embodiments, two, bridged seven-membermetallocycles form a symmetrical complex, as shown in the examplesbelow:

where the complex includes two metallocycles bound by a single bridginggroup.

In still other embodiments, metal-ligand complexes according to theinvention may be characterized by the general formula:

wherein each of AR, M, L, B, and n′, are as defined above; and thedotted lines indicate possible binding to the metal atom, provided thatat least two of the dotted lines are covalent bonds.

In this regard it is to be noted that L_(n′) indicates that the metal Mis bonded to a number n′ groups of L, as defined above.

It is to be further noted that, in one preferred embodiment, B is abridge of between about 3 and about 50 carbon atoms (not includinghydrogen atoms), and more preferably is a bridge of between about 3 andabout 20 carbon atoms.

In still other embodiments, metal-ligand complexes according to theinvention can be characterized by the general formula:

wherein each of R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹², R¹³, R¹⁴, R¹⁵, R¹⁶,R¹⁷, R¹⁸, and R¹⁹ defined above for structure (II), and M, L, n′, B, areas defined above and as further explained in connection with structure(V). The dotted lines indicate possible binding to the metal atom,provided that at least two of the dotted lines are covalent bonds.

In more specific embodiments, R² and R¹² are selected from the groupconsisting of an aryl and a heteroaryl; R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹,R¹³, R¹⁴, R¹⁵, R¹⁶, R¹⁷, R¹⁸ and R¹⁹ are defined as above; and B is:

In another particular embodiment, R² and R¹² are independently selectedfrom the group consisting of substituted or unsubstituted moieties ofthe general formulae:

R⁴ and R¹⁴ are each an alkyl; R³, R⁵, R⁶, R⁷, R⁸, R⁹, R¹³, R¹⁵, R¹⁶,R¹⁷, R¹⁸ are hydrogen, and B is selected from the group consisting of:

In more specific embodiments, the metal-ligand complexes of thisinvention may be characterized by the general formula:

wherein R², R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, M, L, n′, and B are as definedabove and as further explained in connection with structure V. Thedotted lines indicate possible binding to the metal atom, provided thatat least two of the dotted lines are covalent bonds.

In another particular embodiment, R² is selected from the groupconsisting of an aryl and a heteroaryl; R⁴ is an alkyl; R³, R⁵, R⁶, R⁷,R⁸, R⁹ are hydrogen; and B is:

wherein Q, R⁶⁰, and m′ are as defined above.

In another particular embodiment, R² is selected from the groupconsisting of substituted or unsubstituted moieties of the generalformulae:

wherein R⁴ is an alkyl; and R³, R⁵, R⁶, R⁷, R⁸ and R⁹ are defined asabove, and B is selected from the group consisting of:

In some embodiments, M is selected from the group consisting of Hf andZr.

In addition, Lewis base adducts of the metal-ligand complexes in theabove formulas may be suitable, for example, ethers, amines, thioethers,phosphines and the like are suitable as Lewis bases.

Specific metal-ligand complexes within the scope of the inventioninclude Group 4 metal complexes formed from any of the ligands set outin Table 1, above.

In one embodiment, the metal-ligand complexes are selected from thegroup consisting of:

wherein L is selected from the group consisting of Cl, Br, Bn, NMe₂,NEt₂ and N(SiMe₃)₂; R₁, R₂, R₃ and R₄ are each hydrogen or an alkyl; andM is selected from the group consisting of Zr and Hf. In anotherembodiment, the metal-ligand complex is selected from the groupconsisting of:

wherein L is selected from the group consisting of Cl, Br, Bn, NMe₂,NEt₂ and N(SiMe₃)₂, and M is selected from the group consisting of Zrand Hf.

In a particular embodiment, the metal-ligand complex is selected fromthe group consisting of:

Metal-Ligand Complex Preparation

The metal-ligand complexes can be formed by techniques known to those ofskill in the art, such as combinations of metal precursors and ligandsunder conditions to afford complexation. For example, the complexes ofthis invention can be prepared according to the general scheme shownbelow:

As shown in Scheme 13, a ligand according to formula II is combined withthe metal precursor M(L)_(n) under conditions to cause the removal of atleast 2 leaving group ligands L, which are shown in the scheme ascombining with a hydrogen (H). Other schemes where the leaving groupligand combines with other moieties (e.g., Li, Na, etc.) employing otherknown routes for complexation can be used, including for example,reactions where the ligand L reacts with other moieties (e.g., where thealkali metal salt of the ligand is used and the complexation reactionproceeds by salt elimination).

Activators for the Metal-Ligand Complexes

The metal-ligand complexes and compositions are active catalysts incombination with a suitable activator, combination of activators,activating technique or activating package, as well as a suitablesupport, although some of the ligand-metal complexes may be activewithout an activator or activating technique depending on theligand-metal complex and on the process being catalyzed. Broadly, theactivator(s) may comprise alumoxanes, Lewis acids, Bronsted acids,compatible non-interfering activators and combinations of the foregoing.These types of activators have been taught for use with differentcompositions or metal complexes in the following references, which arehereby incorporated by reference in their entirety: U.S. Pat. No.5,599,761, U.S. Pat. No. 5,616,664, U.S. Pat. No. 5,453,410, U.S. Pat.No. 5,153,157, U.S. Pat. No. 5,064,802, EP-A-277,004 and Marks et al.,Chem. Rev. 2000, 100, 1391-1434. In some embodiments, ionic or ionforming activators are preferred. In other embodiments, alumoxaneactivators are preferred.

Suitable ion forming compounds useful as an activator in one embodimentcomprise a cation that is a Bronsted acid capable of donating a proton,and an inert, compatible, non-interfering, anion, A⁻. Suitable anionsinclude, but are not limited to, those containing a single coordinationcomplex comprising a charge-bearing metal or metalloid core.Mechanistically, the anion should be sufficiently labile to be displacedby olefinic, diolefinic and unsaturated compounds or other neutral Lewisbases such as ethers or nitriles. Suitable metals include, but are notlimited to, aluminum, gold and platinum. Suitable metalloids include,but are not limited to, boron, phosphorus, and silicon. Compoundscontaining anions that comprise coordination complexes containing asingle metal or metalloid atom are, of course, well known and many,particularly such compounds containing a single boron atom in the anionportion, are available commercially.

Specifically, such activators may be represented by the followinggeneral formula:(L*-H)_(d) ⁺(A^(d−))wherein L* is a neutral Lewis base; (L*-H)⁺ is a Bronsted acid; A^(d−)is a non-interfering, compatible anion having a charge of d−, and d isan integer from 1 to 3. More specifically A^(d−) corresponds to theformula: (M′³⁺Q_(h))^(d−) wherein h is an integer from 4 to 6; h−3=d; M′is an element selected from group 13 of the periodic table; and Q isindependently selected from the group consisting of hydrogen,dialkylamido, halogen, alkoxy, aryloxy, hydrocarbyl, andsubstituted-hydrocarbyl radicals (including halogen substitutedhydrocarbyl, such as perhalogenated hydrocarbyl radicals), said Q havingup to 20 carbons. In a more specific embodiment, d is one, i.e., thecounter ion has a single negative charge and corresponds to the formulaA.

Activators comprising boron or aluminum can be represented by thefollowing general formula:(L*-H)⁺(JQ4)⁻wherein: L* is as previously defined; J is boron or aluminum; and Q is afluorinated C₁₋₂₀ hydrocarbyl group. Most specifically, Q isindependently selected from the group consisting of fluorinated arylgroup, such as a pentafluorophenyl group (i.e., a C₆F₅ group) or a3,5-bis(CF₃)₂C₆H₃ group. Illustrative, but not limiting, examples ofboron compounds which may be used as an activating cocatalyst in thepreparation of the improved catalysts of this invention aretri-substituted ammonium salts such as: trimethylammoniumtetraphenylborate, triethylammonium tetraphenylborate, tripropylammoniumtetraphenylborate, tri(n-butyl)ammonium tetraphenylborate,tri(t-butyl)ammonium tetraphenylborate, N,N-dimethylaniliniumtetraphenylborate, N,N-diethylanilinium tetraphenylborate,N,N-dimethylanilinium tetra-(3,5-bis(trifluoromethyl)phenyl)borate,N,N-dimethyl-(2,4,6-trimethylanilinium)tetraphenylborate,trimethylammonium tetrakis(pentafluorophenyl)borate, triethylammoniumtetrakis(pentafluorophenyl)borate, tripropylammoniumtetrakis(pentafluorophenyl)borate, tri(n-butyl)ammoniumtetrakis(pentafluorophenyl)borate, tri(secbutyl)ammoniumtetrakis(pentafluorophenyl)borate, N,N-dimethylaniliniumtetrakis(pentafluorophenyl)borate, N,N-diethylaniliniumtetrakis(pentafluorophenyl)borate,N,N-dimethyl-(2,4,6-trimethylanilinium)tetrakis(pentafluorophenyl)borate,trimethylammonium tetrakis-(2,3,4,6-tetrafluorophenylborate andN,N-dimethylanilinium tetrakis-(2,3,4,6-tetrafluorophenyl)borate;dialkyl ammonium salts such as: di-(i-propyl)ammoniumtetrakis(pentafluorophenyl)borate, and dicyclohexylammoniumtetrakis(pentafluorophenyl)borate; and tri-substituted phosphonium saltssuch as: triphenylphospnonium tetrakis(pentafluorophenyl)borate,tri(o-tolyl)phosphonium tetrakis(pentafluorophenyl)borate, andtri(2,6-dimethylphenyl)phosphonium tetrakis(pentafluorophenyl)borate;N,N-dimethylanilinium tetrakis(3,5-bis(trifluoromethyl)phenyl)borate;HNMe(C₁₈H₃₇)₂ ⁺B(C₆F₅)₄ ⁻; HNPh(C₁₈H₃₇)₂ ⁺B(C₆F₅)₄ ⁻ and((4-nBu-Ph)NH(n-hexyl)₂)⁺B(C₆F₅)₄ ⁻ and((4-nBu-Ph)NH(n-decyl)₂)⁺B(C₆F₅)₄ ⁻. Specific (L*-H)⁺ cations areN,N-dialkylanilinium cations, such as HNMe₂Ph⁺, substitutedN,N-dialkylanilinium cations, such as (4-nBu-C₆H₄)NH(n-C₆H₁₃)₂ ⁺ and(4-nBu-C₆H₄)NH(n-C₁₀H₂₁)₂ ⁺ and HNMe(C₁₈H₃₇)₂ ⁺. Specific examples ofanions are tetrakis(3,5-bis(trifluoromethyl)phenyl)borate andtetrakis(pentafluorophenyl)borate. In some embodiments, the specificactivator is PhNMe₂H⁺B(C₆F₅)₄ ⁻.

Other suitable ion forming activators comprise a salt of a cationicoxidizing agent and a non-interfering, compatible anion represented bythe formula:(Ox^(e+))_(d)(A^(d−))_(e)wherein: Ox^(e+) is a cationic oxidizing agent having a charge of e+; eis an integer from 1 to 3; and A^(d−), and d are as previously defined.Examples of cationic oxidizing agents include: ferrocenium,hydrocarbyl-substituted ferrocenium, Ag⁺, or Pb⁺². Specific embodimentsof A^(d−) are those anions previously defined with respect to theBronsted acid containing activating cocatalysts, especiallytetrakis(pentafluorophenyl)borate.

Another suitable ion forming, activating cocatalyst comprises a compoundthat is a salt of a carbenium ion or silyl cation and a non-interfering,compatible anion represented by the formula:©⁺A⁻wherein: ©⁺ is a C₁₋₁₀₀ carbenium ion or silyl cation; and A⁻ is aspreviously defined. A preferred carbenium ion is the trityl cation, i.e.triphenylcarbenium. The silyl cation may be characterized by the formulaZ⁴Z⁵Z⁶Si⁺ cation, where each of Z⁴, Z⁵, and Z⁶ is independently selectedfrom the group consisting of hydrogen, halogen, and optionallysubstituted alkyl, alkenyl, alkynyl, heteroalkyl, heteroalkenyl,heteroalkynyl, aryl, heteroaryl, alkoxyl, aryloxyl, silyl, boryl,phosphino, amino, mercapto, alkylthio, arylthio, and combinationsthereof. In some embodiments, a specified activator is Ph₃C⁺B(C₆F₅)₄ ⁻.

Other suitable activating cocatalysts comprise a compound that is asalt, which is represented by the formula (A*^(+a))_(b)(Z*J*_(j))^(−c)_(d) wherein A* is a cation of charge +a; Z* is an anion group of from 1to 50, specifically 1 to 30 atoms, not counting hydrogen atoms, furthercontaining two or more Lewis base sites; J* independently eachoccurrence is a Lewis acid coordinated to at least one Lewis base siteof Z*, and optionally two or more such J* groups may be joined togetherin a moiety having multiple Lewis acidic functionality; j is a numberform 2 to 12; and a, b, c, and d are integers from 1 to 3, with theproviso that a×b is equal to c×d. See, WO 99/42467, which isincorporated herein by reference. In other embodiments, the anionportion of these activating cocatalysts may be characterized by theformula ((C₆F₅)₃M″″-LN-M″″(C₆F₅)₃)⁻ where M″″ is boron or aluminum andLN is a linking group, which is specifically selected from the groupconsisting of cyanide, azide, dicyanamide and imidazolide. The cationportion is specifically a quaternary amine See, e.g., LaPointe, et al.,J. Am. Chem. Soc. 2000, 122, 9560-9561, which is incorporated herein byreference.

In addition, suitable activators include Lewis acids, such as thoseselected from the group consisting of tris(aryl)boranes,tris(substituted aryl)boranes, tris(aryl)alanes, tris(substitutedaryl)alanes, including activators such as tris(pentafluorophenyl)borane.Other useful ion forming Lewis acids include those having two or moreLewis acidic sites, such as those described in WO 99/06413 or Piers, etal. “New Bifunctional Perfluoroaryl Boranes: Synthesis and Reactivity ofthe ortho-Phenylene-Bridged Diboranes 1,2-(B(C₆F₅)₂)₂C₆X₄ (X═H, F)”, J.Am. Chem. Soc., 1999, 121, 3244-3245, both of which are incorporatedherein by reference. Other useful Lewis acids will be evident to thoseof skill in the art. In general, the group of Lewis acid activators iswithin the group of ion forming activators (although exceptions to thisgeneral rule can be found) and the group tends to exclude the group 13reagents listed below. Combinations of ion forming activators may beused.

Other general activators or compounds useful in a polymerizationreaction may be used. These compounds may be activators in somecontexts, but may also serve other functions in the polymerizationsystem, such as alkylating a metal center or scavenging impurities.These compounds are within the general definition of “activator,” butare not considered herein to be ion-forming activators. These compoundsinclude a group 13 reagent that may be characterized by the formulaG¹³R⁵⁰ _(3-p)D_(p) where G¹³ is selected from the group consisting of B,Al, Ga, In and combinations thereof, p is 0, 1 or 2, each R⁵⁰ isindependently selected from the group consisting of hydrogen, halogen,and optionally substituted alkyl, alkenyl, alkynyl, heteroalkyl,heteroalkenyl, heteroalkynyl, aryl, heteroaryl, and combinationsthereof, and each D is independently selected from the group consistingof halogen, hydrogen, alkoxy, aryloxy, amino, mercapto, alkylthio,arylthio, phosphino and combinations thereof. In other embodiments, thegroup 13 activator is an oligomeric or polymeric alumoxane compound,such as methylalumoxane and the known modifications thereof. See, forexample, Barron, “Alkylalumoxanes, Synthesis, Structure and Reactivity”,pp 33-67 in “Metallocene-Based Polyolefins: Preparation, Properties andTechnology”, Edited by J. Schiers and W. Kaminsky, Wiley Series inPolymer Science, John Wiley & Sons Ltd., Chichester, England, 2000, andreferences cited therein. In other embodiments, a divalent metal reagentmay be used that is defined by the general formula M′R⁵⁰ _(2-p),D_(p),and p′ is 0 or 1 in this embodiment and R⁵⁰ and D are as defined above.M′ is the metal and is selected from the group consisting of Mg, Ca, Sr,Ba, Zn, Cd and combinations thereof. In still other embodiments, analkali metal reagent may be used that is defined by the general formulaM″R⁵⁰ and in this embodiment R⁵⁰ is as defined above. M″ is the alkalimetal and is selected from the group consisting of Li, Na, K, Rb, Cs andcombinations thereof. Additionally, hydrogen and/or silanes may be usedin the catalytic composition or added to the polymerization system.Silanes may be characterized by the formula SiR⁵⁰ _(4-q)D_(q) where R⁵⁰is defined as above, q is 1, 2, 3 or 4 and D is as defined above, withthe proviso that there is at least one D that is a hydrogen.

The activator or a combination of activators may be supported on anorganic or inorganic support. Suitable supports include silicas,aluminas, clays, zeolites, magnesium chloride, polystyrenes, substitutedpolystyrenes. The activator may be co-supported with the metal-ligandcomplex. Suitable metal-ligand supports are more fully described in thesection entitled “Catalyst Supports” below.

The molar ratio of metal:activator (whether a composition or complex isemployed as a catalyst) employed specifically ranges from 1:10,000 to100:1, more specifically from 1:5000 to 10:1, most specifically from1:10 to 1:1. In one embodiment of the invention mixtures of the abovecompounds are used, particularly a combination of a group 13 reagent andan ion-forming activator. The molar ratio of group 13 reagent toion-forming activator is specifically from 1:10,000 to 1000:1, morespecifically from 1:5000 to 100:1, most specifically from 1:100 to100:1. In another embodiment, the ion forming activators are combinedwith a group 13 reagent. Another embodiment is a combination of theabove compounds having about 1 equivalent of an optionally substitutedN,N-dialkylanilinium tetrakis(pentafluorophenyl)borate, and 5-30equivalents of a group 13 reagent. In some embodiments from about 30 to2000 equivalents of an oligomeric or polymeric alumoxane activator, suchas a modified alumoxane (e.g., alkylalumoxane), can be used.

In other applications, the ligand will be mixed with a suitable metalprecursor compound prior to or simultaneous with allowing the mixture tobe contacted to the reactants. When the ligand is mixed with the metalprecursor compound, a metal-ligand complex may be formed, which may be acatalyst.

Catalyst Supports

The ligands, complexes or catalysts may be supported on organic orinorganic supports, in combination with an appropriate activator, inorder to obtain the supported catalyst of the present invention.Suitable supports include silicas, aluminas, clays, zeolites, magnesiumchloride, polystyrenes, substituted polystyrenes and the like. Polymericsupports may be cross-linked or not. Similarly, the ligands, complexes,catalysts or activators may be supported on supports known to those ofskill in the art. See for example, Hlatky, Chem. Rev. 2000, 100,1347-1376 and Fink et al., Chem. Rev. 2000, 100, 1377-1390, both ofwhich are incorporated herein by reference. The compositions, complexesand/or catalysts may be contacted with an activator (described above)before or after contact with the support; alternatively, the support maybe contacted with the activator prior to contact with the composition,complex or catalyst. In addition, the catalysts of this invention may becombined with other catalysts in a single reactor and/or employed in aseries of reactors (parallel or serial) in order to form blends ofpolymer products.

In one embodiment, the loading of the metal-ligand complex deposited onthe support is from about 1 μmol/gram of supported catalyst to about 100μmol/gram of supported catalyst. In another embodiment, the loading isfrom about 2 μmol/gram of supported catalyst to about 100 μmol/gram ofsupported catalyst and, in another embodiment, from about 4 μmol/gram ofsupported catalyst to about 100 μmol/gram of supported catalyst. Inanother embodiment, the loading of the metal-ligand complex deposited onthe support is from about 1 μmol/gram of supported catalyst to about 50μmol/gram of supported catalyst. In another embodiment, the loading isfrom about 2 μmol/gram of supported catalyst to about 50 μmol/gram ofsupported catalyst and, in another embodiment, from about 4 μmol/gram ofsupported catalyst to about 50 μmol/gram of supported catalyst. In otherembodiments, the loading of the metal-ligand complex deposited on thesupport is from about 1 μmol/gram of supported catalyst to about 25μmol/gram of supported catalyst, from about 2 μmol/gram of supportedcatalyst to about 25 μmol/gram of supported catalyst or from about 4μmol/gram of supported catalyst to about 25 μmol/gram of supportedcatalyst. In other embodiments, the loading of the metal-ligand complexdeposited on the support is from about 1 μmol/gram of supported catalystto about 20 μmol/gram of supported catalyst, from about 2 μmol/gram ofsupported catalyst to about 20 μmol/gram of supported catalyst or fromabout 4 μmol/gram of supported catalyst to about 20 μmol/gram ofsupported catalyst. In further embodiments, the loading of themetal-ligand complex deposited on the support is from about 1 μmol/gramof supported catalyst to about 15 μmol/gram of supported catalyst, fromabout 2 μmol/gram of supported catalyst to about 15 μmol/gram ofsupported catalyst or from about 4 μmol/gram of supported catalyst toabout 15 μmol/gram of supported catalyst. In additional embodiments, theloading of the metal-ligand complex deposited on the support is fromabout 1 μmol/gram of supported catalyst to about 10 μmol/gram ofsupported catalyst, from about 2 μmol/gram of supported catalyst toabout 10 μmol/gram of supported catalyst or even from about 3 μmol/gramof supported catalyst to about 10 μmol/gram of supported catalyst. Inother embodiments, the loading of the metal-ligand complex deposited onthe support is about 1 μmol/gram of supported catalyst, about 2μmol/gram, about 4 μmol/gram, about 10 μmol/gram, about 20 μmol/gram,about 30 μmol/gram, about 40 μmol/gram, about 50 μmol/gram or even about100 μmol/gram.

Two different metal-ligand complexes may be deposited on the organic orinorganic support to form a two component co-supported catalyst. Suchtwo component catalysts are particularly useful for the production ofbimodal ultra-high molecular weight polyethylene. In one embodiment, thetotal loading of the two metal-ligand complexes deposited on the supportis from about 1 μmol/gram of supported catalyst to about 100 μmol/gramof supported catalyst. In another embodiment, the total loading of themetal-ligand complexes deposited on the support is from about 2μmol/gram of supported catalyst to about 100 μmol/gram of supportedcatalyst and, in another embodiment, from about 4 μmol/gram of supportedcatalyst to about 100 μmol/gram of supported catalyst. In oneembodiment, the total loading of the two metal-ligand complexesdeposited on the support is from about 1 μmol/gram of supported catalystto about 50 μmol/gram of supported catalyst. In another embodiment, thetotal loading of the metal-ligand complexes deposited on the support isfrom about 2 μmol/gram of supported catalyst to about 50 μmol/gram ofsupported catalyst and, in another embodiment, from about 4 μmol/gram ofsupported catalyst to about 50 μmol/gram of supported catalyst. Infurther embodiments, the loading of the metal-ligand complexes depositedon the support is from about 1 μmol/gram of supported catalyst to about25 μmol/gram of supported catalyst, from about 2 μmol/gram of supportedcatalyst to about 25 μmol/gram of supported catalyst or from about 4μmol/gram of supported catalyst to about 25 μmol/gram of supportedcatalyst. In other embodiments, the loading of the metal-ligandcomplexes deposited on the support is from about 1 μmol/gram ofsupported catalyst to about 20 μmol/gram of supported catalyst, fromabout 2 μmol/gram of supported catalyst to about 20 μmol/gram ofsupported catalyst or from about 4 μmol/gram of supported catalyst toabout 20 μmol/gram of supported catalyst. In additional embodiments, theloading of the metal-ligand complexes deposited on the support is fromabout 1 μmol/gram of supported catalyst to about 10 μmol/gram ofsupported catalyst, from about 2 μmol/gram of supported catalyst toabout 10 μmol/gram of supported catalyst or even from about 4 μmol/gramof supported catalyst to about 10 μmol/gram of supported catalyst. Inother embodiments, the loading of the metal-ligand complexes depositedon the support is about 1 μmol/gram of supported catalyst, about 2μmol/gram, about 4 μmol/gram, about 10 μmol/gram, about 20 μmol/gram,about 30 μmol/gram, about 40 μmol/gram, about 50 μmol/gram or even about100 μmol/gram.

When two metal-ligand complexes are deposited on the support, the molarratio of the first complex to the second complex may be about 1:1, oralternatively the supported two-component complex may include a molarexcess of one of the complexes relative to the other. For example, theratio of the first complex to the second complex may be about 1:2; about1:3; about 1:5; about 1:10; about 1:20 or more. In one embodiment, theratio of the first metal-ligand complex to the second metal-ligandcomplex deposited on the support is between about 1:1 and 1:10 and inanother embodiment between about 1:1 to about 1:5. Further, the ratiomay be adjusted as needed and may be determined experimentally in orderto obtain a bimodal composition with a target split between the highmolecular weight component and the low molecular weight polyethylenecomponent.

Utilization of Supported Ligand-Metal Complexes as Catalyst

The supported catalysts of the invention can be used to catalyze avariety of transformations, including, for example, oxidation,reduction, hydrogenation, hydrosilylation, hydrocyanation,hydroformylation, polymerization, carbonylation, isomerization,metathesis, carbon-hydrogen activation, carbon-halogen activation,cross-coupling, Friedel-Crafts acylation and alkylation, hydration,Diels-Alder reactions, Baeyer-Villiger reactions, and othertransformations. Some compositions, complexes and/or catalysts accordingto the invention are particularly effective at polymerizing ethylene toobtain a UHMWPE polymer, or a bimodal polymer composition comprisingUHMWPE. Alternatively, however, some compositions, complexes and/orcatalysts according to the invention are particularly effective atpolymerizing α-olefins (such as propylene, 1-butene, 1-pentene,1-hexene, 1-heptene, 1-octene, and styrene), copolymerizing ethylenewith α-olefins (such as propylene, 1-butene, 1-pentene, 1-hexene,1-heptene, 1-octene, and styrene), copolymerizing ethylene with1,1-disubstituted olefins (such as isobutylene), or copolymerizingethylene, propylene and a diene monomer suitable for production of EPDM(Ethylene-Propylene-Diene Monomer) synthetic rubbers. Thus, for example,in some embodiments, metal-ligand compositions and complexes containingzirconium or hafnium may be useful in the polymerization of ethylenealone, or in combination with one or more α-olefins, as noted above.

In general, monomers useful herein may be olefinically unsaturatedmonomers having from 2 to 20 carbon atoms either alone or incombination. Generally, monomers may include olefins (including cyclicolefins), diolefins and unsaturated monomers including ethylene and C₃to C₂₀ α-olefins such as propylene, 1-butene, 1-hexene, 1-octene,4-methyl-1-pentene, 1-norbornene, styrene and mixtures thereof;additionally, 1,1-disubstituted olefins, such as isobutylene,2-methyl-1-butene, 2-methyl-1-pentene, 2-ethyl-1-pentene,2-methyl-1-hexene, 3-trimethylsilyl-2-methyl-1-propene,α-methyl-styrene, either alone or with other monomers such as ethyleneor C₃ to C₂₀ α-olefins and/or diolefins; additionally 1,2-substitutedolefins, such as 2-butene. The α-olefins listed above may be polymerizedin a stereospecific manner—for example, as in the generation ofisotactic or syndiotactic or hemiisotactic polypropylene. Additionallythe α-olefins may be polymerized to produce a polymer with differingtacticity sequences within the polymer chain, such as polypropylenecontaining atactic and isotactic sequences within the same polymerchain. Diolefins generally comprise 1,3-dienes such as (butadiene),substituted 1,3-dienes (such as isoprene) and other substituted1,3-dienes, with the term substituted referring to the same types ofsubstituents referred to above in the definition section. Diolefins alsocomprise 1,5-dienes and other non-conjugated dienes, such asethylidene-norbornene, 1,4-hexadiene, dicyclopentadiene and other dienesused in the manufacture of EPDM synthetic rubbers. The styrene monomersmay be unsubstituted or substituted at one or more positions on the arylring. The use of diolefins in this invention is typically in conjunctionwith another monomer that is not a diolefin.

More specifically, it has been found that the catalysts of the presentinvention are particularly active for certain monomers, particularlyethylene or α-olefins. Polymers that can be prepared according to thepresent invention include ethylene copolymers with at least one C₃-C₂₀α-olefin, particularly propylene, 1-butene, 1-hexene, 4-methyl-1-penteneand 1-octene. The copolymers of ethylene with at least one C₃-C₂₀α-olefin comprise from about 0.1 mol.% α-olefin to about 50 mol.%α-olefin, more specifically from about 0.2 mol.% α-olefin to about 30mol.% α-olefin and still more specifically from about 2 mol.% α-olefinto about 5 mol.% higher olefin.

The α-olefins listed above may be polymerized in a stereoselectivemanner to produce a substantially stereoregular polymer product (thatis, a polymer product that is detectably enriched in m or r dyads (asdetermined, e.g., by ¹³C NMR) as compared to a corresponding atacticmaterial), as in the generation of isotactic, syndiotactic orhemiisotactic poly-α-olefins and as more fully described in U.S. Pat.No. 7,060,848, the entire contents of which are incorporated herein byreference for all relevant and consistent purposes.

Novel polymers, copolymers or interpolymers may be formed having uniquephysical and/or melt flow properties. Polymers that can be preparedaccording to the present invention include copolymers of ethylene andone or more α-olefins, such as copolymers of ethylene with at least oneC₄-C₂₀ α-olefin, such as 1-butene, 1-hexene, 4-methyl-1-pentene,1-octene or styrene. Similarly, the techniques described herein can beused to prepare propylene copolymers with at least one C₄-C₂₀ α-olefin.In some embodiments, the copolymers of ethylene or propylene with atleast one C₄-C₂₀ α-olefin comprise from about 0.01 mol.% higher olefinto about 50 mol.% higher olefin, more specifically from about 0.1 mol.%higher olefin to about 50 mol.% higher olefin and still morespecifically from about 1 mol.% higher olefin to about 30 mol.% higherolefin. For certain embodiments of this invention, crystallinecopolymers include those of ethylene and a comonomer selected from thegroup consisting of 1-butene, 1-hexene, 1-octene and styrene comprisefrom about 0.1 to about 50 mol.% comonomer, more specifically from about1 to about 20 mol. % comonomer, even more specifically from about 2 toabout 15 mol. % comonomer and most specifically from about 5 to about 12mol. % comonomer.

Polymerization is carried out under polymerization conditions, includingtemperatures of from −100° C. to 300° C. and pressures from atmosphericto 3000 atmospheres. Suspension, solution, slurry, gas phase orhigh-pressure polymerization processes may be employed with thecatalysts and compounds of this invention. Such processes can be run ina batch, semi-batch or continuous mode. Examples of such processes arewell known in the art. A support for the catalyst may be employed, whichmay be inorganic (such as alumina, magnesium chloride or silica) ororganic (such as a polymer or cross-linked polymer). Methods for thepreparation of supported catalysts are known in the art. Slurry,suspension, gas phase and high-pressure processes as known to thoseskilled in the art may also be used with supported catalysts of theinvention.

Other additives that are useful in a polymerization reaction may beemployed, such as scavengers, promoters, modifiers and/or chain transferagents, such as hydrogen, aluminum alkyls and/or silanes.

As discussed herein, catalytic performance can be determined a number ofdifferent ways, as those of skill in the art will appreciate. Catalyticperformance can be determined by the yield of grams of polymer obtainedper gram of catalyst per hour or as the yield of grams of polymer pergrams of catalyst metal per hour, which in some contexts may beconsidered to be activity. The examples provide data for thesecomparisons.

Another measure of catalyst polymerization performance is co-monomerincorporation. As is well known in the art, many ethylene copolymers areprepared using ethylene and at least one other monomer. These copolymersor higher order polymers in some applications require higher amounts ofadditional co-monomer(s) than have been practical with known catalysts.Since ethylene tends to be the most reactive monomer, obtaining higherco-monomer incorporations is a benefit that is examined forpolymerization catalysts. Two useful co-monomers are 1-octene andstyrene. This invention offers the possibility of higher incorporationof co-monomers such as 1-octene and styrene.

As stated herein, a solution process is specified for certain benefits,with the solution process being run at a temperature above 90° C., morespecifically at a temperature above 100° C., further more specificallyat a temperature above 110° C. and even further more specifically at atemperature above 130° C. Suitable solvents for polymerization arenon-coordinating, inert liquids. Examples include straight andbranched-chain hydrocarbons such as isobutane, butane, pentane,isopentane, hexane, isohexane, heptane, octane, Isopar-E® and mixturesthereof; cyclic and alicyclic hydrocarbons such as cyclohexane,cycloheptane, methylcyclohexane, methylcycloheptane, and mixturesthereof; perhalogenated hydrocarbons such as perfluorinated C₄₋₁₀alkanes, chlorobenzene, and aromatic and alkyl substituted aromaticcompounds such as benzene, toluene, mesitylene, and xylene. Suitablesolvents also include liquid olefins which may act as monomers orcomonomers including ethylene, propylene, 1-butene, butadiene,cyclopentene, 1-hexene, 1-pentene, 3-methyl-1-pentene,4-methyl-1-pentene, 1,4-hexadiene, 1-octene, 1-decene, isobutylene,styrene, divinylbenzene, allylbenzene, and vinyltoluene (including allisomers alone or in admixture). Mixtures of the foregoing are alsosuitable.

In addition to polymerization of olefinic monomers, the ligands,compositions, and complexes according to the invention can beincorporated in catalysts for the selective dimerization, trimerizationor oligomerization of olefinic monomers, such as the selectivetrimerization of ethylene to 1-hexene. See, for example, Forni andInvernizzi, Ind. Eng. Chem. Process Des. Develop. 1973, 12, 455-459;Svejda and Brookhart, Organometallics 1999, 18, 65-75; Agapie et al., J.Am. Chem. Soc. 2004, 126, 1304-1305; Carter et al., Chem. Comm. 2002,858-859; Deckers et al., Organometallics 2002, 21, 5122-5135; McGuinnesset al., Chem. Comm. 2003, 334-335; McGuinness et al., J. Am. Chem. Soc.2003, 125, 5272-5273; EP 1,110,930; WO 02/083306; and WO 01/48028.

The ligands, metal-ligand complexes and compositions of this inventioncan be prepared and tested for catalytic activity in one or more of theabove reactions in a combinatorial fashion as described in U.S. Pat. No.7,060,848, the entire contents of which are incorporated herein byreference for all relevant and consistent purposes.

Methods for Polymerizing Polyethylene by the Use of Supported Catalysts

The supported catalysts described herein (i.e., a catalyst comprising asupport, an activator, and one or more metal-ligand complexes) areparticularly well suited for use in the production of very-high orultra-high molecular weight polyethylene. According to one embodiment ofthe present invention, a supported catalyst as described herein isutilized to produce a very-high or ultra-high molecular weightpolyethylene composition of a specific target molecular weight. Themethod includes selecting a target molecular weight of the polyethylenecomposition and correlating the target molecular weight to the loadingof a metal-ligand complex on a support. After the loading of themetal-ligand complex on the support has been determined, one or moremonomers are contacted with a supported catalyst having the correlatedmetal-ligand loading.

According to another embodiment of the present invention for preparing avery-high or ultra-high molecular weight polyethylene composition, thecomposition of the metal-ligand complex, i.e., the specific metal-ligandcomplex utilized in the polymerization reaction, is chosen to provide atarget molecular weight of the polyethylene composition. According tothe method, a target molecular weight of the polyethylene composition isselected and the target molecular weight is correlated to a specificmetal-ligand complex on a support. One or more monomers are contactedwith the supported catalyst to produce the polyethylene compositionhaving the targeted molecular weight.

In another embodiment, a bimodal polyethylene composition is produced bycontacting one or more monomers with a two component co-supportedcatalyst (i.e., a catalyst comprising two different metal-ligandcomplexes). The polyethylene composition includes a first polyethylenecomponent that is a very-high or an ultra-high molecular weightcomponent or portion and a second polyethylene component that is avery-high or high molecular weight polyethylene component or portion.One of the metal-ligand complexes deposited on the support produces thefirst polyethylene component and the other metal-ligand complexdeposited on the support produces the second polyethylene component. Insome embodiments, the weight ratio of the first component versus thesecond polyethylene component may range from about 1:10 to about 10:1;or from about 1:4 to about 4:1; or from about 1:2 to about 2:1. In someembodiments, the ratio of the first polyethylene component to the secondpolyethylene component is about 1:1.

EXAMPLES

It is to be noted that, in addition to the Examples provided below,other examples related to the synthesis of specific ligands suitable foruse in the present invention may be found, for example, in WO2005/108406 and WO 2003/091262, the entire contents of which areincorporated herein by reference for all relevant and consistentpurposes.

All reactions in Examples 1-4 were performed under a purified argon ornitrogen atmosphere in a Vacuum Atmospheres or MBraun glove box. Allsolvents were anhydrous, de-oxygenated and purified according to knowntechniques. All ligands and metal precursors were prepared according toprocedures known to those of skill in the art, e.g., under inertatmosphere conditions, etc. Polymerizations were carried out in aparallel pressure reactor, which is fully described in U.S. Pat. No.6,548,026, which is incorporated herein by reference.

High temperature Size Exclusion Chromatography was performed using anautomated “Rapid GPC” system as described in U.S. Pat. No. 6,491,816,U.S. Pat. No. 6,491,823, U.S. Pat. No. 6,475,391, U.S. Pat. No.6,461,515, U.S. Pat. No. 6,436,292, U.S. Pat. No. 6,454,947, and6,855,258, the entire contents of which are incorporated herein byreference for all relevant and consistent purposes. The device usedfeatures a series of two 30 cm×7.5 mm linear columns containing PLgel 20um Mixed-A (available from Polymer Labs). The system was operated at aneluent flow rate of 1.5 mL/min and an oven temperature of 165° C.O-dichlorobenzene was used as the eluent. The polymer samples weredissolved in 1,2,4-trichlorobenzene at a concentration of about 1 mg/mL.About 200 μL of a polymer solution was injected into the system. Theconcentration of the polymer in the eluent was monitored using anevaporative light scattering detector. The GPC system was calibratedusing 8 commercial UHMWPE materials with reported Margolies molecularweights. The molecular weight results are given relative to thecommercial sample Margolies molecular weights. Conventional sizeexclusion chromatography was performed using a Polymer Labs PL210instrument equipped with one 30 cm PL Mixed-A column (available fromPolymer Labs). The system was operated at an eluent flow rate of 0.5mL/min and an oven temperature of 165° C. 1,2,4-trichlorobenzene wasused as the eluent. The polymer samples were dissolved1,2,4-trichlorobenzene at a concentration of about 2 mg/mL. Theconcentration of the polymer in the eluent was monitored using arefractive index detector. High temperature Size ExclusionChromatography methods for ultra-high molecular weight polymers,including UHMWPE, is described in detail in Xu et al., Macromol. RapidCommun., 1998, 19, pp 115-118, and Aust, J. Biochem. Biophys. Methods,2003, 56, pp 323-334.

Examples of metal-ligand complexes are shown below:

All ligands were synthesized as described in WO 2005/108406. The ligandfor complex A was synthesized similarly to the ligand for complex Bexcept the diol starting material was a mixture of cis- andtrans-pentane-2,4-diol. The ligand for complex C was synthesizedsimilarly starting with MOM-protected mesityl substituted upper ringbuilding block and 2-Me-1,3-propanediol. The ligand for complex D wassynthesized similarly stating with MOM-protected mesityl substitutedupper ring building block and 2-iPr-1,3-propanediol.

The ligands were complexed with Hf(CH₂Ph)₂Cl₂(EtO) (for complex B) andZr(CH₂Ph)₂Cl₂(EtO) (for complexes A, C and D) in toluene at 80-100° C.for 1-3 hours. The reaction mixtures were concentrated and cooled to−30° C. over night. For complexes and D, pentane was added to theconcentrated toluene reaction mixture before cooling. The complexes A-Dwere obtained as crystalline material.

Example 1 Preparation of Silica-Based Supports with a PMAO Activator

Davison 948 Silica previously calcined at 600° C. under nitrogen (1000mg) was placed in a 20 ml scintillation vial. The silica was slurried intoluene (5.33 mL). PMAO-IP (4.666 mL of a 1.5 M solution in toluene) wasadded to the vortexing silica/toluene slurry. The reaction mixture wasslurried for 30 minutes at room temperature and then heated to 50° C.The diluent was then removed by a stream of nitrogen with continuousvortexing and heating at 50° C. A dry material was obtained after 2.5hours. This material was further dried under vacuum at 50° C. for anadditional hour resulting in 1506 mg of PMAO-IP/silica supportedactivator.

Example 2 Preparation of Supported Catalysts with a Single Complex

Around 100 mg PMAO-IP/silica supported activator was weighed into an 8ml vial. Heptane (1 ml) was added and the support was slurried byvortexing. Complex A (0.5 mL of a 1 mM toluene solution) was added tothe silica slurry in heptane and allowed to react for 1 hour at roomtemperature in the capped vial under continuous vortexting. The cap wasreplaced by a septum fitted with needles to enable a nitrogen purge ofthe vial. The reaction mixture was heated to 50° C. under continuousvortexing. The diluents were removed by a stream of nitrogen flowingthroughout the vial via the purge needles for 1 hour, resulting in a dryproduct. Supported catalysts using complex B, C and D were preparedsimilarly, as described in Table 2.

TABLE 2 Preparation conditions for supported catalysts includingmetal-ligand complexes A, B, C and D. Metal- Total complex PMAO-Catalyst solution Catalyst Ligand loading IP/silica 1 mM CompositionComplex [umol/gram] [mg] [uL] 1 A 4.9 102 500 2 B 4.9 103 500 3 C 4.9102 500 4 D 4.9 102 500 Note: Complex loading is calculated asmicromoles of complex per gram of supported activator (PMAO-IP/silica)

Example 3 Preparation of Co-Supported Catalysts Comprising Two Complexes

Around 50 mg PMAO-IP/silica supported activator was weighed into an 8 mlvial. Heptane (0.5 ml) was added and the support was slurried byvortexing. 1 mM toluene solutions of complex A (185 uL) and complex C(160 ul) were combined and added to the PMAO-IP/silica slurry in heptaneand allowed to react for 1 hour at room temperature in the capped vialwith continuous vortexing. The cap was replaced by a septum fitted withpurge needles. The reaction mixture was heated to 50° C. undercontinuous vortexing. The diluents were removed by a stream of nitrogenflowing through the purge needles for 1 hour, resulting in dry product.Three additional catalysts using different combinations of complexeswere similarly prepared as described in Table 3.

TABLE 3 Preparation conditions for two component supported cataqlyststhat each include two metal-ligand complexes selected from A, B, C and DTotal Complex 1 Complex 2 complex Complex Complex Metal- Metal- PMAO-Solution Solution loading 1 loading 2 loading Catalyst Ligand LigandIP/silica (1 mM) (1 mM) [umol/ [umol/ [umol/ Composition Complex 1Complex 2 [mg] [uL] [uL] gram] gram] gram] 5 A C 51.5 189.6 165.8 6.93.7 3.2 6 A D 50.6 186.3 96 5.6 3.7 1.9 7 B C 51.3 724.7 165.2 17.3 14.13.2 8 B D 51.2 723.3 97.1 16 14.1 1.9 Note: Complex loadings arecalculated as micromoles of complex per gram of supported activator(PMAO-IP/silica)

Example 4 Ethylene Polymerizations Using Catalysts from Examples 2 and 3

A total of 8 separate polymerization reactions were performed. Apre-weighed glass vial insert and disposable stirring paddle were fittedto each reaction vessel of the reactor. The reactor was then closed andthe atmosphere inside the reactor was replaced with ethylene. 0.25 mL ofa 0.02 M solution of TIBA (triisobutyl aluminum) in heptane followed bythe amount of heptane listed in Table 4, were injected into eachpressure reaction vessel through a valve (with specific diluent amountsfor each polymerization example being listed in Table 4). Thetemperature was then set to 90° C. and the stirring speed was set to 800rpm, and the mixture was exposed to ethylene at a pressure of 150 psi.An ethylene pressure of 150 psi in the pressure cell and the temperaturesetting were maintained, using computer control, until the end of thepolymerization experiment.

TABLE 4 Diluent amounts for each polymerization reaction. SupportedSupported Heptane Heptane Catalyst catalyst catalyst heptane ChaserBuffer Composition slurry [ul] slurry [mg] [ul] [ul] [ul] 1 100 0.2 4050480 120 2 400 0.8 3850 400 100 3 100 0.2 4050 480 120 4 100 0.2 4050 480120 5 100 0.2 4050 480 120 6 100 0.2 4050 480 120 7 100 0.2 4050 480 1208 100 0.2 4050 480 120

The supported metal-ligand complexes prepared in Examples 2 and 3 wereused for the polymerization reactions. A catalyst (12 mg) was weighedinto an 8 mL vial, and 6 mL of docedene was added as diluent. The vialwas shaken and then placed onto a vortexer. The suspended catalystslurry was aspirated into a fine gauged needle from the vortexing vialand a heptane “buffer” volume was aspirated to act as barrier. Thebuffer followed by the catalyst was injected into the prepressurizedreaction vessel and was followed immediately by injection of heptane“chaser” volume. Table 4 shows the amount of catalyst injected for eachof the eight compositions.

The polymerization reaction was allowed to continue for between about1900 and 4400 seconds, during which time the temperature and pressurewere maintained at their pre-set levels by computer control. Thespecific polymerization times for each polymerization are shown in Table5. After the reaction time elapsed, the reaction was quenched byaddition of an overpressure of carbon dioxide sent to the reactor. Thepolymerization times were the lesser of the maximum desiredpolymerization time or the time taken for a predetermined amount ofmonomer (ethylene) gas to be consumed in the polymerization reaction.

TABLE 5 Polymerization time for each polymerization reaction. CalculatedActivity Margolies MWD [g/g Activity MW derived (Mw/Mn) SupportedReaction supported [g/g from Rapid from Catalyst time Yield catalyst *catalyst GPC Rapid identity [seconds] [mg] hr] metal * hr] [g/mol] GPC]1 4381 170 699 1,564,200 6,570,400 1.6 2 3597 175 219 250,390 7,505,2251.7 3 3676 175 856 1,91,550 2,494,630 2.3 4 1980 177 1610 3,30,2802,457,920 2.1 5 2872 178 1257 1,997,500 2,529,825 7.4 6 3436 182 11612,273,300 10,120,460 2.2 7 2938 177 1076 383,100 4,327,953 3.6 8 3487178 1513 562,430 5,458625 2.8

After the polymerization reaction was completed, the glass vial insert,containing the polymer product and diluent, was removed from thepressure cell and removed from the inert atmosphere dry box, and thevolatile components were removed using a centrifuge vacuum evaporator.After most of the volatile components had evaporated, the vial contentswere dried thoroughly by evaporation at elevated temperature underreduced pressure. The vial was then weighed to determine the yield ofpolymer product. The polymer product was then analyzed by Rapid GPC, asdescribed above to determine the molecular weight and molecular weightdistribution (MWD) of the polymers produced. The molecular weights & MWDare shown in Table 5. The Rapid GPC chromatograms for each correspondingproduct polymer are shown in FIGS. 1-8, showing the ELSD signal versusretention time for the polymer products of supported catalysts 1-8respectively. Longer retention times correspond to lower molecularweight polymers. The figures show that narrow MWD products can beobtained from the supported catalyst 1-4 each comprising a singlecomplex and that broaded MWD or bimodal MWD can be obtained from theco-supported catalysts 5-8 each comprising two co-supported complexes,For the high-throughput Rapid GPC method used, the separation at thehighest molecular weights is not ideal, and the MWD (Mw/Mn) isunderestimated. Thus, the polymer product from the polymerizationexample from Supported Catalyst 5 was also analyzed using conventionalsize exclusion chromatography using a Polymer Labs PL210high-temperature GPC instrument as described above, to determine a moreaccurate MWD. This conventional method gave a Mw value of 2.6×10⁶ and aMWD (Wm/Mn) of 13.

A number of embodiments the methods, metal-ligand complexes andsupported catalysts (i.e., a support have an activator and one or moremetal-ligand complexes deposited thereon) of the invention have beendescribed. Nevertheless, it will be understood that variousmodifications may be made without departing from the spirit and scope ofthe invention. Accordingly, other embodiments are within the scope ofthe following claims.

When introducing elements of the present invention or the preferredembodiments(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

As various changes could be made in the above apparatus and methodswithout departing from the scope of the invention, it is intended thatall matter contained in the above description and shown in theaccompanying figures shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. A slurry polymerization method for producing avery-high or ultra-high molecular weight polyethylene composition, themethod comprising contacting one or more monomers with a supportedcatalyst, the supported catalyst comprising: a support, a metal-ligandcomplex deposited on the support at a loading from about 1 μmol/gram ofsupported catalyst to about 100 μmol/gram of supported catalyst, themetal-ligand complex characterized by the general formula:

wherein the O-AR-AR-O—B—O-AR-AR-O fragment of the general formula isdefined by a ligand selected from the group consisting of

wherein at least two of the bonds from the oxygens (O) to M arecovalent, with the other bonds being dative; M is a metal selected fromthe group consisting of Hf and Zr; each L is independently a moiety thatforms a covalent dative or ionic bond with M; and n′ is 1, 2, 3 or 4;and, an activator.
 2. A method as set forth in claim 1 wherein thesupport is selected from the group consisting of silicas, aluminas,clays, zeolites, magnesium chloride, polystyrenes and substitutedpolystyrenes.
 3. A method as set forth in claim 1 wherein the loading ofthe metal-ligand complex deposited on the support is from about 1μmol/gram of supported catalyst to about 50 μmol/gram of supportedcatalyst.
 4. A method as set forth in claim 1 wherein the polyethylenecomposition is an ultra-high molecular weight polyethylene compositionwith a weight average molecular weight of between about 3×10⁶ g/mol andabout 20×10⁶ g/mol.
 5. A method as set forth in claim 1 wherein thepolyethylene composition is an ultra-high molecular weight polyethylenecomposition with a weight average molecular weight of between about3×10⁶ g/mol and about 15×10⁶ g/mol.
 6. A method as set forth in claim 1wherein the polyethylene composition is an ultra-high molecular weightpolyethylene composition with a weight average molecular weight ofbetween about 3×10⁶ g/mol and about 10×10⁶ g/mol.
 7. A method as setforth in claim 1 wherein the polyethylene composition is a very-highmolecular weight polyethylene composition with a weight averagemolecular weight of between about 1×10⁶ g/mol and about 3×10⁶ g/mol. 8.A method as set forth in claim 1 wherein the polyethylene composition isa very-high molecular weight polyethylene composition with a weightaverage molecular weight of between about 2×10⁶ g/mol and about 3×10⁶g/mol.
 9. A method as set forth in claim 1 wherein at least two monomersare contacted with the supported catalyst.
 10. A method as set forth inclaim 9 wherein at least one of the monomers is ethylene and one of themonomers is an α-olefin.
 11. A slurry polymerization method forproducing a very-high or ultra-high molecular weight polyethylenecomposition, the method comprising contacting one or more monomers witha supported catalyst, the supported catalyst comprising: a support, ametal-ligand complex deposited on the support at a loading from about 1μmol/gram of supported catalyst to about 100 μmol/gram of supportedcatalyst, the metal-ligand complex characterized by the general formula:

wherein at least two of the bonds from the oxygens (0) to M arecovalent, with the other bonds being dative; and wherein each of R² andR¹² is

each of R³, R⁴, R⁵, R⁶, R⁷, R⁸, R⁹, R¹³, R¹⁴, R¹⁵, R¹⁶, R¹⁷, R¹⁸ and R¹⁹is independently selected from the group consisting of hydrogen,halogen, and optionally substituted hydrocarbyl, heteroatom-containinghydrocarbyl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, alkylthio,arylthio, nitro, and combinations thereof; optionally two or more Rgroups can combine together into ring structures, with such ringstructures having from 3 to 12 atoms in the ring, not counting hydrogenatoms; B is a bridging group having from 3 to 50 atoms not countinghydrogen atoms and is selected from the group consisting of optionallysubstituted divalent hydrocarbyl and optionally substituted divalentheteroatom-containing hydrocarbyl; M is a metal selected from the groupconsisting of Hf and Zr; each L is independently a moiety that forms acovalent dative or ionic bond with M; and n′ is 1, 2, 3 or 4; whereinthe O—B—O fragment is:

wherein each Q is independently selected from the group consisting ofcarbon and silicon, each R⁶⁰ is independently selected from the groupconsisting of hydrogen and optionally substituted hydrocarbyl andheteroatom containing hydrocarbyl, provided that at least one R⁶⁰substituent is not hydrogen, wherein the R⁶⁰ substituents are optionallyjoined into a ring structure having from 3 to 50 atoms in the ringstructure not counting hydrogen atoms, and m′ is 0, 1, 2 or 3; and, anactivator.